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GS650GZ Katana Rebuild (Historical)

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    #16



    MikesXS emulators to suit the 6-fiddy's spindly 35mm forks.
    sigpicDarryl from Kiwiland

    1982 GSX1100S Katana
    1982 GSX750S Katana
    1982 GS650G Katana

    Comment


      #17
      Repainted the frame black on the weekend. Lower fork legs also painted.



      Some fork parts arrived from Webike. So I'll drill some holes in the damping rods and start putting these back together. Rear tyre fitted and balanced. But noticed the white paint was flaking off. P.O obviously didnt understand surface prep... Can't be arsed repainting the wheel at this stage... It looks a little diseased...



      Need to paint the brake parts and get new hoses, may be paint the engine... Oh, and give the bodywork a coat of paint. But will be bolting things back together.
      sigpicDarryl from Kiwiland

      1982 GSX1100S Katana
      1982 GSX750S Katana
      1982 GS650G Katana

      Comment


        #18
        And the bolting back together begins.


        sigpicDarryl from Kiwiland

        1982 GSX1100S Katana
        1982 GSX750S Katana
        1982 GS650G Katana

        Comment


          #19
          Damping rods drilled for emulators


          sigpicDarryl from Kiwiland

          1982 GSX1100S Katana
          1982 GSX750S Katana
          1982 GS650G Katana

          Comment


            #20
            DIY Fork straightening










            The top of the fork tube deviated by about 5 -6 mm when rotated with the lower fork leg clamped in a vice.


            Once I parted the the fork tube I identified the high point on tube by rolling it on a piece of plate glass. I then used a dial gauge set up on a small truing stand that I made for two-stroke cranks and identified the straight sections of the tube. I rotated the tube on the truing stand on the straight sections and measured a deviation of about 1.9mm at the high point.


            I made some wooden shoes to spread the load from the press and pressed down on the high spot until I detected some movement on the tube end that wasn't the wood compressing. It took a couple of cautious tries to get an idea of the pressure required to bend the tube.


            The result wasn't perfect (I didn't expect it to be). But the high point deviation is about 0.3 mm with a similar deviation when rotating the assembled fork. So not too bad a result and it cost me no money. And spending as little on this bike as I can get away with is the point of this exercise.
            Last edited by KiwiAlfa156; 10-11-2021, 07:37 PM.
            sigpicDarryl from Kiwiland

            1982 GSX1100S Katana
            1982 GSX750S Katana
            1982 GS650G Katana

            Comment


              #21
              A few more 'ingredients' for Pete





              sigpicDarryl from Kiwiland

              1982 GSX1100S Katana
              1982 GSX750S Katana
              1982 GS650G Katana

              Comment


                #22
                Sanded, primed and guide coated.








                Tank after Evaporust on the inside, before work begins.





                sigpicDarryl from Kiwiland

                1982 GSX1100S Katana
                1982 GSX750S Katana
                1982 GS650G Katana

                Comment


                  #23
                  Examining the tank there were wide 'ring' patterns of rust bubbles under the paint. A little exploratory sanding revealed rust on the margins of bog patches. So being an unknown quantity, out with the paint stripper.







                  A bit of work to do....







                  Not too bad...





                  Weld spots where the top of the tank has been pulled out. Its been smacked up at some stage.


                  sigpicDarryl from Kiwiland

                  1982 GSX1100S Katana
                  1982 GSX750S Katana
                  1982 GS650G Katana

                  Comment


                    #24
                    Phosphoric acid treatment after a good seeing to with P60 grit on a random orbital sander.





                    After washing a layer of etch primer





                    Areas requiring filler now really obvious with etch primer. And yes filler sticks to this. Not as good as a 2-pack Urethane Primer, but it is a rust killer.


                    sigpicDarryl from Kiwiland

                    1982 GSX1100S Katana
                    1982 GSX750S Katana
                    1982 GS650G Katana

                    Comment


                      #25
                      Got the slapper out and "reversed the damage" as much as possible tapping down the high creases flat





                      Bog on... Got the basic shape back. Next is blocking back and looking for profile, ripples and pinholes.



                      sigpicDarryl from Kiwiland

                      1982 GSX1100S Katana
                      1982 GSX750S Katana
                      1982 GS650G Katana

                      Comment


                        #26
                        I've picked a colour after quite a bit of 'umming and ahhing'. It's not a strict resto, and there is enough 13L on the 1100. I once owned an 1100EZ and a 190E 2.3-16 Cosworth liked the bronze metallic colour that was on both of them. And so went for Mercedes Smoke Silver.


                        sigpicDarryl from Kiwiland

                        1982 GSX1100S Katana
                        1982 GSX750S Katana
                        1982 GS650G Katana

                        Comment


                          #27
                          Blade putty fix for pin holes and minor imperfections








                          Several coats of primer filler and guide coat.








                          Blocked down and mud guard bottom in satin black.








                          Base coat in Smoke Silver. Just decals and clearcoat to go





                          sigpicDarryl from Kiwiland

                          1982 GSX1100S Katana
                          1982 GSX750S Katana
                          1982 GS650G Katana

                          Comment


                            #28
                            I guess the question is how tidy is the 'tidy' in 'tidy-up'? In reality this project has become about how much can I do myself? And be cost effective.


                            I did the decals and sprayed some clear. Being acrylic I willhave to wait a while before cutting back and polishing.





                            sigpicDarryl from Kiwiland

                            1982 GSX1100S Katana
                            1982 GSX750S Katana
                            1982 GS650G Katana

                            Comment


                              #29
                              Colour in natural light.


                              sigpicDarryl from Kiwiland

                              1982 GSX1100S Katana
                              1982 GSX750S Katana
                              1982 GS650G Katana

                              Comment


                                #30
                                Finished the final coats of clear. Did a bit of experiment with gun setting, pressure and material viscosity and got it to lay flat and wet. A bit of orange peel, but ill give it 60 days and then cut and polish.











                                Waiting for the Katana emblems to arrive to finish the side covers. Will start on the engine tidy up tomorrow night.
                                sigpicDarryl from Kiwiland

                                1982 GSX1100S Katana
                                1982 GSX750S Katana
                                1982 GS650G Katana

                                Comment

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