1981 GSX1100 Katana Based Project

[Shin-Ken 1074]

Aluminium number plate bracket fitted.


number plate bracket2 by Max Mutarn, on Flickr


Number plate bracket by Max Mutarn, on Flickr


Running tally = 172,793 grams.

[Shin-Ken 1074]

It's from hidden parts that you see the care and the refinement puu into a project.

Thank you Lorenzo, you have a good eye and an understanding of hidden detail.

[Shin-Ken 1074]

Rear tail light time, swapping the OEM for a lighter model. After making an aluminium bracket, it sits neatly in the duck-tail and has a similar vertical profile to the OEM lens.

tail light 1 by Max Mutarn, on Flickr


tail light 2 by Max Mutarn, on Flickr


tail light 3 by Max Mutarn, on Flickr


Running tally = 173,207 grams.

[Shin-Ken 1074]

Tank test fit without cap or tap.


DW fuel tank by Max Mutarn, on Flickr


tank no tap or cap by Max Mutarn, on Flickr

Running tally = 176,137 grams.

[Shin-Ken 1074]

Seat test fit.


DW seat bodywork weight by Max Mutarn, on Flickr


seat 1 by Max Mutarn, on Flickr


Running tally = 178,937 grams.

[Shin-Ken 1074]

Seat lock.

seat lock by Max Mutarn, on Flickr


Running tally = 179,144 grams.

[Shin-Ken 1074]

No many parts left on the shelf now, screen, indicators, brake lines, fuel cap and tap, speedo and throttle cable, horn, exhaust system.. Hhhmmmm, tempted to weigh them all together and see what I have.

[Shin-Ken 1074]

A few more parts installed today:

fins
fuel cap
front indicators
screen

carbon fins by Max Mutarn, on Flickr


fuel cap by Max Mutarn, on Flickr


OEM front indicators by Max Mutarn, on Flickr


DW carbon screen by Max Mutarn, on Flickr

[Shin-Ken 1074]

Getting closer to the finish line now.


cowl 1a by Max Mutarn, on Flickr


tank1 by Max Mutarn, on Flickr


I still need to make a headlight surround, muffler bracket and rear indicator brackets. Other jobs are to fit the fuel tap, paint the horn and install exhaust system and rear indicators and cables.

Will also overhaul the front and rear calipers with new kits as well as overhaul the front and rear master cylinders with new kits. Once that is done it's off to the Wizard to sort out the electrics.


Running tally = 179,667 grams.

[Shin-Ken 1074]

Pics from todays work.

DW decals by Max Mutarn, on Flickr


DW a1 by Max Mutarn, on Flickr

[Lorenzo]

On the leitmotiv of the thread, I seem that, by halving the clacsons of post # 370 in two, you could see a weight saving of 27gr out of nothing (single clacson = 282gr twin = 509/2 = 254gr)

I'm starting to dig this bike;

[Rob S.]

What do we estimate this Kat will do in the quarter mile? I'll venture high nines with a good, light rider. Maybe 130 mph at the end.

[Shin-Ken 1074]

On the leitmotiv of the thread, I seem that, by halving the clacsons of post # 370 in two, you could see a weight saving of 27gr out of nothing (single clacson = 282gr twin = 509/2 = 254gr)

I'm starting to dig this bike;

Yes, the twin horn weight when halved would be like you say = 254 g and lighter than the single horn. Turns out each horn is the same weight and it is the brackets that account for the difference in weight, the single bracket is heavier than it should be because of where it was designed to be mounted. With an alternative horn position there is no reason why the new bracket can not be smaller and lighter. That's the plan for now.

OEM twin horn by Max Mutarn, on Flickr


The solution is to make a smaller bracket in aluminium to replace the steel OEM single bracket. My estimate is the single horn with an ally bracket should come in at around 246 grams.


OEM single horn bracket by Max Mutarn, on Flickr

[Shin-Ken 1074]

What do we estimate this Kat will do in the quarter mile? I'll venture high nines with a good, light rider. Maybe 130 mph at the end.

With the focus on shedding weight above all else unfortunately performance had to take a backseat on this build. However, with an improved power to weight ratio there will be some gain in performance. I think it would be a struggle for high nines or even 10's and 11's but whatever it could do would still be fun?

[Shin-Ken 1074]

Had a chance to sort out the lighter horn bracket today. I have used thin ally for the bracket and with 253 grams hanging on the bracket I decided to use a triangular bracket to offer better support, a few grams heavier but eliminates the chance of the horn moving if it was attached with a single bolt.



DWhorn12 by Max Mutarn, on Flickr



DWhorn13 by Max Mutarn, on Flickr


DWhorn14 by Max Mutarn, on Flickr


DWhorna10 by Max Mutarn, on Flickr