1981 GSX1100 Katana Based Project

[Shin-Ken 1074]

Your attention to detail on this project is amazing.
I have just used 0000 steel wool and a Back to Black reconditioner on black plastic. Looks great for a couple months. I will try your method on the next round.

Hi Steve, thank you, yes, I do like details! Have 1000g wet sanded the rear guard and used black plastic treatment on it. It will never look like new but it looks O.K. and certainly much better than it did before the tidy up so I am happy with it. Any of the plastic treatment products I have used over the years have needed follow up buffing every few months depending on use and weather of course. Here where I live it is Sun damage, Queensland UV is pretty harsh.

 

[Shin-Ken 1074]

Agree 100% with what steve murdoch said. It's clear that this is a passion project.

Passion or obsession? Depending on the day it can be either or both!

Cheers.

 

[Shin-Ken 1074]

Using a very soft foam pad and 1000g paper I have sanded the guard ensuring to start at the top section and drag the pad in one direction towards the bottom edge of the guard. Run the pad past the edge of the guard and start again from the top. Use the pad in straight lines and overlap with each pass. Once sanded I used a plastic treatment product as directed on the bottle. Although not perfect it is presentable and with regular buffing it should stay looking good.


Rear guard 10 by Max Mutarn, on Flickr


Rear guard 11 by Max Mutarn, on Flickr


Rear guard 13 by Max Mutarn, on Flickr


Rear guard 14 by Max Mutarn, on Flickr


Rear guard 15 by Max Mutarn, on Flickr

 

[Shin-Ken 1074]

Rear guards now installed. Forward section of the guard including OEM grommets.


Rear guard 17 by Max Mutarn, on Flickr


Rear section of the guard with modified washers, M8 nylon bolts and M6 allen bolts.

Rear guard 16 by Max Mutarn, on Flickr


Running tally = 169,202 grams.

 

[Shin-Ken 1074]

Rear guard done.

Rear guard 18 by Max Mutarn, on Flickr


Why use nylon bolts? Lightest bolts available and only used in areas that don't impact on safety. These are the four bolts for the front guard, Ti vs nylon.

Front guard Ti bolts by Max Mutarn, on Flickr


Front guard nylon bolts by Max Mutarn, on Flickr

 

[Shin-Ken 1074]

OEM rear indicator with OEM steel mount bracket. Aluminium and file time!

OEM indicator steel mount by Max Mutarn, on Flickr

 

[Shin-Ken 1074]

The aluminium clutch cable pivot lever and Ti bolt fitted to the DW 180. Not much I can do to lighten this one so it will have to stay the way it is.


Ally clutch cable pivot by Max Mutarn, on Flickr

 

[Lorenzo]

Mirrors and lock by Max Mutarn, on Flickr

Roadriders are a very fine choice

 

[Shin-Ken 1074]

Roadriders are a very fine choice

Hi Lorenzo, what are Roadriders?

 

[Shin-Ken 1074]

Comparing OEM headlight and cowl frame to DW headlight and ally cowl frame.

OEM headlight and frame by Max Mutarn, on Flickr


DW headlight by Max Mutarn, on Flickr


DW headlight subframe by Max Mutarn, on Flickr


DW headlight frame by Max Mutarn, on Flickr


OEM assembly = 2,370g vs 1,257 g for the DW assembly.

 

[steve murdoch]

Hi Lorenzo, what are Roadriders?

Are the tires Avon Roadrider Mark 2?

 

[Shin-Ken 1074]

Are the tires Avon Roadrider Mark 2?

Thanks Steve, got it now. For the project I went with Bridgestone Battlax T32 Radial tyres. Lightest radial tyre I could find for an 18" x 2.50 front and 18" x 3.50 rear that has good performance in wet and dry conditions.


Bridgestone Radial by Max Mutarn, on Flickr

 

[Shin-Ken 1074]

Cowl, frame and headlight fitted.


OEM cowl by Max Mutarn, on Flickr


Running tally = 171,668 grams.

 

[Shin-Ken 1074]

A milestone event today, the Kat is off the bench and on her wheels for the first time at the start of her new life. Had three friends help lift her off the bench and to make it easier to lift, the rear guard and cowl were removed so we could grab the frame and forks and not damage anything. Wow, a great feeling seeing her on the deck at last, still smiling!

23 Nov 23 on wheels 1 by Max Mutarn, on Flickr


23 Nov 23 on wheels 2 by Max Mutarn, on Flickr

 

[Shin-Ken 1074]

Tomorrow taking her out for the day to have new HEL brake lines made and fitted. Now that she is off the bench and not resting on the OEM sump I can replace the OEM sump with a modified and lighter sump which means the running tally will be reduced, happy times!

The modified sump.
DW sump by Max Mutarn, on Flickr

 

[Lorenzo]

Had three friends help lift her off the bench and to make it easier to lift, the rear guard and cowl were removed so we could grab the frame and forks and not damage anything.

Eerr It shouldn't have been that bad after all the effort put in before...

 

[Rob S.]

Yes, with all that weight shaved and saved, I'd have thought you could have done it single handed.

Remind us, is she close to about 400 lbs?

 

[Shin-Ken 1074]

Eerr It shouldn't have been that bad after all the effort put in before...

We had been drinking Rum for the afternoon so four bodies to lift her down seemed like a good idea, that way if we dropped her she would fall on someone and not damage the new paint.

 

[Shin-Ken 1074]

Yes, with all that weight shaved and saved, I'd have thought you could have done it single handed.

Remind us, is she close to about 400 lbs?

Err, yeah,nar, enjoying a few Rums and relaxing, talking bikes with the crew and then the light bulb flashed on, while the bodies are here let's lift her off the bench. Job done and back to the drinks.

Weight wise as of yesterday = 379 lbs.

 

[Shin-Ken 1074]

If it's Friday it must be brake line day. Had these made today at the local HEL agent.

HEL lines 1 by Max Mutarn, on Flickr


HEL lines 2 by Max Mutarn, on Flickr


HEL line 3 by Max Mutarn, on Flickr