Starter motor is now in place, starter and bolts = 1,522 grams.
Running tally = 150,592 grams.
Running tally = 150,592 grams.
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1981 GSX1100 Katana Based Project
- Thread starter Shin-Ken 1074
- Start date
The starter motor cover is one of the parts I made in carbon, the first two were total fails as you can see with this sad example.
Starter cover 1 by Max Mutarn, on Flickr
Got it on the third try.
Carbon cover by Max Mutarn, on Flickr
Starter cover 1 by Max Mutarn, on FlickrGot it on the third try.
Carbon cover by Max Mutarn, on Flickr
OEM steel starter cover.
SZ OEM starter cover by Max Mutarn, on Flickr
Carbon cover and bolts.
Carbon cover and bolts by Max Mutarn, on Flickr
DW Carbon Cover by Max Mutarn, on Flickr
Running tally = 150,617 grams.
SZ OEM starter cover by Max Mutarn, on FlickrCarbon cover and bolts.
Carbon cover and bolts by Max Mutarn, on FlickrDW Carbon Cover by Max Mutarn, on FlickrRunning tally = 150,617 grams.
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Replacing steel parts with aluminium parts has helped to reduce weight for the DW 180 however, there are times when steel is lighter than aluminium. What form of skullduggery is this! The OEM clip-ons are solid aluminium and with the bar weights come in at 1,474 g. I found a used set of hollow steel clip-ons with aluminium bar weights that are 1,153 g. And the steel bars are also adjustable so the angle can go from a flat bar position down to the point where they will crush your fingers against the tank on full lock.
OEM bars.
OEM bars by Max Mutarn, on Flickr
DW 180 bars
DW bars by Max Mutarn, on Flickr
OEM bars.
OEM bars by Max Mutarn, on FlickrDW 180 bars
DW bars by Max Mutarn, on Flickr
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I bought these bars because they are lighter than the stock bars however, I really like the additional feature of adjustment, from flat bars to full on drop bars.
DW bars 2 by Max Mutarn, on Flickr
Dw bars 1 by Max Mutarn, on Flickr
Running tally = 151,770 grams.
DW bars 2 by Max Mutarn, on FlickrDw bars 1 by Max Mutarn, on FlickrRunning tally = 151,770 grams.
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Carbon chain guard now installed.
DW carbon guard by Max Mutarn, on Flickr
DW carbon chain guard by Max Mutarn, on Flickr
Running tally = 151,918 grams.
DW carbon guard by Max Mutarn, on FlickrDW carbon chain guard by Max Mutarn, on FlickrRunning tally = 151,918 grams.
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Shaved oil filter cover, Ti nuts and washer and filter. No oil in engine at this stage as the DW will be going on the scales dry.
DW oil cover by Max Mutarn, on Flickr
Running tally = 152,193 grams.
DW oil cover by Max Mutarn, on FlickrRunning tally = 152,193 grams.
Cleaned up the clutch before fitting the newly painted cover.
DW clutch 1 by Max Mutarn, on Flickr
Clutch cover ready to go.
DW clutch cover and bolts by Max Mutarn, on Flickr
DW clutch cover installed by Max Mutarn, on Flickr
Running tally = 153,179 grams.
DW clutch 1 by Max Mutarn, on FlickrClutch cover ready to go.
DW clutch cover and bolts by Max Mutarn, on FlickrDW clutch cover installed by Max Mutarn, on FlickrRunning tally = 153,179 grams.
Saved a few grams swapping the OEM rubber grips for foam grips that are less than half the weight of the OEM grips.
OEM grips by Max Mutarn, on Flickr
Foam grips by Max Mutarn, on Flickr
OEM grips by Max Mutarn, on FlickrFoam grips by Max Mutarn, on Flickr
Rijko
Forum Sage
did you remove weight from the clutch cover ?
Seeing how far you go to save weight, did you consider a billet clutch cover, or one with a window ?
Expensive stuff.
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LarsKroghStea
Forum Mentor
OEM steel starter cover.
Carbon cover and bolts.
Running tally = 150,617 grams.
Thats pretty cool
Do you think it's possible to mould engine and front sprocket covers the same way? More layers of course, but it would save alot of weight.
Yes, light weight and can help with absorbing vibration if needed.
Hi Rob, I have used Oxford Grab-Ons on other bikes however, these are Johar grips. I like the barrel profile and they hold up pretty well to use and UV exposure. I bought these a few years ago from a supplier in the States and wonder if they are still being made?
Johar grips by Max Mutarn, on Flickr
Thats pretty cool
Hi Lars, not being an Engineer I don't know what level of stress and heat a carbon engine case would need to deal with and the life-cycle of carbon as an engine component under continual stress so from the technical aspect perhaps someone else here has an answer to that question? The cost would be considerable, many thousands of US dollars and perhaps for a part with a limited life?
Front sprocket cover would be easy. For a basic carbon cover just make a flat carbon plate and use aluminium bolts and spacers. There are many versions of sprocket covers using aluminium plate and there could be a carbon version available somewhere?
I modified a stock sprocket cover because I had a spare cover and wanted to see how light I could make it. A carbon cover would be much lighter so maybe in future that could be an option for the project?
Cheers.
Found my spare OEM 630 sprocket. I think it must be from a Leopard tank not a bike!
OEM 630 sprocket by Max Mutarn, on Flickr
Replaced it with this.
DW 520 sprocket by Max Mutarn, on Flickr
OEM 630 sprocket by Max Mutarn, on FlickrReplaced it with this.
DW 520 sprocket by Max Mutarn, on Flickr
Hi Rijko,
I thought about billet cases/covers early in the project and discovered that most of them are heavier than stock parts, are very expensive and even if they were lighter they are beyond my budget for the project. For a lot less cost than billet parts buying titanium bolts and modifying parts will save more weight.
Used a stock clutch cover with Ti bolts.
Cheers.
The OEM airbox and filter are being deleted and for now will use the OEM rubber carb intake boots because I have a set on the carbs.
Carb intake 1 by Max Mutarn, on Flickr
Carb intake 1 by Max Mutarn, on Flickr
The original plan was to use foam filters, a great product and does the job however, now there is a Plan B.
Carb intake 7 by Max Mutarn, on Flickr
Carb intake 7 by Max Mutarn, on Flickr
