750 Katana Resurrection

[KiwiAlfa156]

Minimal time at the moment, so just nudging things forward by doing small jobs



Sanded back, plastic primer/etch primer, then spray putty rubbed back with a Scotch Brite. Next will be primer filler and rub back for color.

[KiwiAlfa156]

Waiting for engine parts to arrive. So thought I'd press on with the panel and paint. The tank is pretty beat up under the filler. It's been drilled and pulled out on one side. I'll be cutting the filler back to steel to make sure there's no rust under the filler. I'll then treat the surface, lay some etch-primer and then refill, shape and undercoat.



Tried to find OEM Blue and White GS1000SN tank decals, but they are as rare as rocking horse droppings with a price to match. So I found a local guy to make some very close replicas. Also some custom ones for the small scoops below the fairing and a small one to test clear coat on. In my minds eye, the white and blue will work in contrast to the Tiger Mica base coat. Guess we'll see.

[KiwiAlfa156]

Seasons greetings and Happy New Year. It's been a couple of weeks since I've spent some time on the Kat. I've pushed on with the body work and will start the rebuild of the engine when the paint is drying.

I cut most of the filler out, primed, filled and sanded back the tank to the correct basic shape with the minimum of Bondo. Primer filler needs to be rubbed back and skimmed and puttied in a few places. Have given the fairing a wet sand with 320 grit ready for primer filler. There is some plastic welding in the tail cowl and the side covers to do. I've not plastic welded yet, but I'll let YouTube be my guide. Got to make pins for the side covers to replace the broken ones.

[psyguy]

Happy New Year mate

It's all coming together nicely!

[KiwiAlfa156]

Seat repaired and recovered. Was missing some foam and had a big hole.

Cut and patched


Shaped


EVA skin


Recovered

[KatManDoo]

Talk about determined..!! A real labour of patience and devotion. Good for you Darryl. Great work. Your resourcefulness is commendable. I picked up some really good info from this thread, especially regarding frame material specs. How on earth you managed to uncover that particular nugget I have no idea. But good info to have. Hopefully some final pics of the bike will be coming soon.

[KiwiAlfa156]

Talk about determined..!! A real labour of patience and devotion. Good for you Darryl. Great work. Your resourcefulness is commendable. I picked up some really good info from this thread, especially regarding frame material specs. How on earth you managed to uncover that particular nugget I have no idea. But good info to have. Hopefully some final pics of the bike will be coming soon.

Thanks KatManDoo. Still a work in progress, slowed by the New Zealand summer vacations and other distractions. I enjoy doing my bit for 'Kat Rescue', and old school Suzuki preservation in general. Been continuously obsessed with Katanas since I first saw an Eleven parked on the street in 1982. Owned an Kawasaki S3 at the time. Horrible bike, but I'd kill to have it today. Got panel and painting to finish and have all the bits to do the engine, so there will be more posts and many more pics. Stay tuned.

[KiwiAlfa156]

The time consuming bit

Blade putty on the imperfections revealed by the primer filler.




Next is a wet sand with 320, may be another coat of primer filler/wet sand and then it'll be ready for base coat.

Side panels and tail cowl to repair and paint prep. Looking forward to spraying colour.



My first plastic weld

[KiwiAlfa156]

Managed to make a good pair of side covers out of four wrecked ones. Plastic welding and chemical welding with acetone/ABS slurry to repair the broken studs and screw tabs



Got to the point of diminishing returns on tank and panel prep, so sprayed the first base coat color, Tiger Mica.



It's not show pony perfect, but good enough that I won't look at it and feel regret. Good enough for an occasional ride, which is her intended use

Wet sanded the primer filler with 600. The water sheets on the primer when it's rinsed and gives a good indicator of how ultimately the clear coat will sit. The reflections in the water are what you look at







I'm going to mask off and spray the second color, Black Pearl. Flat back, a coat of clear,.decals and pin strips, followed by two wet coats of clear. Then the engine work begins.

[alke46]

Amazing how good new paint looks, even if it is not the final color. Keep on keeping on.

[KiwiAlfa156]

Amazing how good new paint looks, even if it is not the final color. Keep on keeping on.

Thanks Larry, the Black Pearl will be on the top of the tank, the front of the fairing, back of the front fender and a stripe across the tail. The Tiger Mica is the main color.

[dorkburger]

I like that color. Resembles the original Hayabusa.

[KiwiAlfa156]

My first attempt at painting a second color and masking pin stripes. Actually it's the second time I've spray painted a bike bodywork. A few tiny bleeds but all nowhere they will be obvious.



Black Pearl









I'm tossing up whether to add some white or silver pin stripe tape. Either way I'll spray clear, flat back, apply the decals and then lay wet coats of clear.

[GSXR7ED]

That is beautiful work on the paint job!

Great work on everything else too.

Thanks for documenting your build.

Ed

****

[KiwiAlfa156]

That is beautiful work on the paint job!

Great work on everything else too.

Thanks for documenting your build.

Ed

****

Thanks Ed, for your kind words. Been a slow process as I'm 'time poor', but finishing the body work will be a real milestone. Bodywork, electrical and rolling chassis will be complete, and only engine and exhaust remain to do. Painting is rewarding because all the prep work finally begins to bear fruit and you see results. I've decided that I will do a complete tear down of the gearbox as the bike has had a very hard life and I'd kick myself if I got everything buttoned up and it jumps out of gear, or worse. Of course I'll be documenting that process too.