1981 GSX1100 Katana Based Project

[jdub6092]

Bingo!

Ti pipes, aluminium flanges, Ti header bolts, Ti and carbon muffler, all used parts except the bling Ti bolts. Working on the muffler bracket. The muffler was cheap to buy as it had been in a prang and was in a pretty poor state. Needed some work to get it sorted and able to do its job.

Aluminium flange and Ti bolts by Max Mutarn, on Flickr


Ti pipes Ti and carbon muffler by Max Mutarn, on Flickr

Did you fabricate these aluminum split flange clamps?
Any special trick to doing this? I can see where the cuts need to be made, but what kind of fine cutting tool did you use?

[Shin-Ken 1074]

Did you fabricate these aluminum split flange clamps?
Any special trick to doing this? I can see where the cuts need to be made, but what kind of fine cutting tool did you use?

Hi jdub6092, I didn't make the ally exhaust flanges, I scored them used from an auction site. I have made a lot of the parts used in this build and if you couldn't find a set of these for sale somewhere, they could be made however, it would be many, many hours of work.

[Shin-Ken 1074]

The new Wiseco pins and pin clips are all the same weight, thankfully. Will also weigh them again with all the parts together to confirm weights and how much each piston has to be shaved.


1197 tapered pin by Max Mutarn, on Flickr




1197 pin clip by Max Mutarn, on Flickr

[Shin-Ken 1074]

The combined weights are consistent, each complete piston weight equals the combined weight of each part. It confirms number 1 piston being 2 grams lighter than the rest. A double bonus for the build after pistons 2,3 and 4 have been shaved;

1) balanced piston set

2) piston set will be six grams lighter

1197 piston1 by Max Mutarn, on Flickr


1197 piston 2 by Max Mutarn, on Flickr


1197 piston3 by Max Mutarn, on Flickr


1197 piston4 by Max Mutarn, on Flickr

[Shin-Ken 1074]

I removed one of the stock 1135cc pistons today and was pleasantly surprised. The Wiseco 1197 cc piston is 26 grams lighter than the stock 1135 cc piston. So with the four 1197cc pistons being 104 grams lighter and the four 76mm bores being 820 grams lighter than the stock bores the total weight reduction is:

924 grams.

When the three pistons are shaved to match number one piston weight there will be another few grams off. Wow, Iam very happy to reduce the weight by that much and have an increase in performance, whats not to like.


1135 OEM piston by Max Mutarn, on Flickr

Running Tally = 198.281 kg.

[Shin-Ken 1074]

Number one piston and pin are the lightest of the set at 291.5 grams, number four piston and pin are the heaviest at 292.6 grams so number four is the first one for a haircut. Used a burr to remove the offending 1.1 grams from number four piston and now it is a match with number one piston and pin at 291.5 grams. Used the serious scales for the piston weight, it weighs in 1 tenth of a gram increments.

1197 # 4 piston before by Max Mutarn, on Flickr


1197 #4 piston burr by Max Mutarn, on Flickr


1197 #4 191.5 by Max Mutarn, on Flickr

[Shin-Ken 1074]

Piston number three has been shaved and now matches Piston 1 and 4 at 291.5 grams.


1197 #3 291.5 by Max Mutarn, on Flickr

[Shin-Ken 1074]

Piston number 2 has been shaved and now all four pistons and pins are the same weight at 291.5 grams.

Running Tally = 198.279


1197#1 piston 291.5 by Max Mutarn, on Flickr


1197 #2 291.5 by Max Mutarn, on Flickr

[Shin-Ken 1074]

I have been looking at the muffler and I think there is some metal that could be trimmed from the inlet end-cap, maybe something like 30-40 grams?

[Shin-Ken 1074]

Looked over the muffler today and there isn't any wiggle room there to remove any metal from the inlet cap. It's spring mounted and cutting it back may weaken it. Plan B is to hog out the ignition timing cover, should be around 70 grams that can be removed from the cover. I have bought a used road rashed cover to be the Lab-rat so no harm will be done to a wholesome cover. The ignition cover should be here in a week or so.

[Shin-Ken 1074]

The Titanium headers to collector on the Kat are the spring connecting type however, I think they are extra weight. The collector uses a solid mount to the frame so the collector can't move and the headers are bolted to the head so they can't move. My thinking is I don't need the springs that connect the headers to the collector because everything is held firmly in place at each end so there isn't a need for the springs to hold the headers to the collector. Going to try it and see what happens.


Running Tally = 198.213 kg


Header Springs1 by Max Mutarn, on Flickr

[Shin-Ken 1074]

With the front collector springs removed there is no need to keep the rear springs, one in all in or one out all out. This has been a good week removing weight from the build, another 1,038 grams lighter.


Running Tally = 198.165 kg

Muffler springs1 by Max Mutarn, on Flickr

[Shin-Ken 1074]

While the pipes are off it will make it easy to clean them and be ready for installing once the engine is back together. Used the Bug/Tar Gel on a cloth then washed the pipes in hot water with dish washing detergent. They don't look like new but they do look pretty good considering the miles on them.


Tipipes1 by Max Mutarn, on Flickr


Tipipes2 by Max Mutarn, on Flickr


Tipipes3 by Max Mutarn, on Flickr


Tipipes4 by Max Mutarn, on Flickr