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1981 GSX1100 Katana Based Project
- Thread starter Shin-Ken 1074
- Start date
No many parts left on the shelf now, screen, indicators, brake lines, fuel cap and tap, speedo and throttle cable, horn, exhaust system.. Hhhmmmm, tempted to weigh them all together and see what I have.
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A few more parts installed today:
fins
fuel cap
front indicators
screen
carbon fins by Max Mutarn, on Flickr
fuel cap by Max Mutarn, on Flickr
OEM front indicators by Max Mutarn, on Flickr
DW carbon screen by Max Mutarn, on Flickr
fins
fuel cap
front indicators
screen
carbon fins by Max Mutarn, on Flickrfuel cap by Max Mutarn, on FlickrOEM front indicators by Max Mutarn, on FlickrDW carbon screen by Max Mutarn, on Flickr
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Getting closer to the finish line now.
cowl 1a by Max Mutarn, on Flickr
tank1 by Max Mutarn, on Flickr
I still need to make a headlight surround, muffler bracket and rear indicator brackets. Other jobs are to fit the fuel tap, paint the horn and install exhaust system and rear indicators and cables.
Will also overhaul the front and rear calipers with new kits as well as overhaul the front and rear master cylinders with new kits. Once that is done it's off to the Wizard to sort out the electrics.
Running tally = 179,667 grams.
cowl 1a by Max Mutarn, on Flickrtank1 by Max Mutarn, on FlickrI still need to make a headlight surround, muffler bracket and rear indicator brackets. Other jobs are to fit the fuel tap, paint the horn and install exhaust system and rear indicators and cables.
Will also overhaul the front and rear calipers with new kits as well as overhaul the front and rear master cylinders with new kits. Once that is done it's off to the Wizard to sort out the electrics.
Running tally = 179,667 grams.
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Yes, the twin horn weight when halved would be like you say = 254 g and lighter than the single horn. Turns out each horn is the same weight and it is the brackets that account for the difference in weight, the single bracket is heavier than it should be because of where it was designed to be mounted. With an alternative horn position there is no reason why the new bracket can not be smaller and lighter. That's the plan for now.
OEM twin horn by Max Mutarn, on FlickrThe solution is to make a smaller bracket in aluminium to replace the steel OEM single bracket. My estimate is the single horn with an ally bracket should come in at around 246 grams.
OEM single horn bracket by Max Mutarn, on Flickr
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With the focus on shedding weight above all else unfortunately performance had to take a backseat on this build. However, with an improved power to weight ratio there will be some gain in performance. I think it would be a struggle for high nines or even 10's and 11's but whatever it could do would still be fun?
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Had a chance to sort out the lighter horn bracket today. I have used thin ally for the bracket and with 253 grams hanging on the bracket I decided to use a triangular bracket to offer better support, a few grams heavier but eliminates the chance of the horn moving if it was attached with a single bolt.
DWhorn12 by Max Mutarn, on Flickr
DWhorn13 by Max Mutarn, on Flickr
DWhorn14 by Max Mutarn, on Flickr
DWhorna10 by Max Mutarn, on Flickr
DWhorn12 by Max Mutarn, on FlickrDWhorn13 by Max Mutarn, on FlickrDWhorn14 by Max Mutarn, on FlickrDWhorna10 by Max Mutarn, on Flickr
DWhorn a9 by Max Mutarn, on Flickr
DWhorn a6 by Max Mutarn, on Flickr
DWhorn a8 by Max Mutarn, on Flickr
DWhorn a7 by Max Mutarn, on Flickr
DWhorn15 by Max Mutarn, on Flickr
DWhorn11 by Max Mutarn, on Flickr
DW horn a5 by Max Mutarn, on Flickr
DW horn a1 by Max Mutarn, on Flickr
DW horn a3 by Max Mutarn, on Flickr
DW horn a4 by Max Mutarn, on FlickrBracket is now ready for paint and those bolts in the pic are not the bolts that will be used for the finished bracket.
My estimate of 246 grams for the new horn and bracket were a bit off.
I just noticed in the 2nd last pic the outer edge of the bracket can be trimmed to match the cowl bracket.
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Trimmed the outer edge and hogged out the bracket to match the cowl bracket hole. Bonus - 1 gram lighter. 1 gram doesn't sound like much but it is the percentage removed from each part that adds up to the weight reduction overall. In this case 1 gram is just under an 8% reduction in weight.
DWhorn18 by Max Mutarn, on Flickr
Bracket 1 by Max Mutarn, on Flickr
bracket2 by Max Mutarn, on Flickr
DWhorn18 by Max Mutarn, on FlickrBracket 1 by Max Mutarn, on Flickrbracket2 by Max Mutarn, on Flickr
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Remember that a box-stock 1983 11ES was the first bike that Cycle World got into the tens (just barely - 10.99). The difference was the 'bikini' fairing.
With a larger engine, and much less weight, your Kat should easily do mid tens. Unless, of course, you're a 500 pound fat slob or measure your self in kilograms, whatever those are. :eagerness:
Kilograms - whatever those are. :biggrin-new:
I am 94 KG so a bit less than 500 lb, before Christmas and New Years anyway!
I've just discovered an area for additional weight savings!
No way, I am not giving up ribs and beer over Christmas! :very_drunk:
Headlight surround today, usual suspect - aluminium.
surround 1 by Max Mutarn, on Flickr
surround2 by Max Mutarn, on Flickr
Surround in primer.
surround5 by Max Mutarn, on Flickr
surround 1 by Max Mutarn, on Flickrsurround2 by Max Mutarn, on FlickrSurround in primer.
surround5 by Max Mutarn, on Flickr
Swapping the OEM steel rear indicator brackets for aluminium brackets.
rear indicator bracket 1 by Max Mutarn, on Flickr
rear indicator bracket 2 by Max Mutarn, on Flickr
rear indicator bracket 3 by Max Mutarn, on Flickr
rear indicator bracket 4 by Max Mutarn, on Flickr
rear indicator bracket 1 by Max Mutarn, on Flickrrear indicator bracket 2 by Max Mutarn, on Flickrrear indicator bracket 3 by Max Mutarn, on Flickrrear indicator bracket 4 by Max Mutarn, on Flickr
Swapped the rear reflector for a lighter (and brighter) version.
RR1 by Max Mutarn, on Flickr
RR2 by Max Mutarn, on Flickr
RR3 by Max Mutarn, on Flickr
RR1 by Max Mutarn, on FlickrRR2 by Max Mutarn, on FlickrRR3 by Max Mutarn, on Flickr
