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1984 Katana 7/11

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Cheers Larry! I'm sure I'm making it a lot more work than it needs to be (I'm good at that) but as long as I get the result I'm looking for it'll be worth it.

There may be another one or two fellas on the KA forum who want one, which is why I spent the time making sure I can re-use the mould.
 
Well, looks like it's good to keep going with the seat!





What you can't really see from the photos is that the front is trimmed a bit high, so it's actually lifting the rear of the tank a little and as a result it's also pushing the seat back a little as well.

The tongue is bolted on and it's sitting nicely on the seat plate though.

So, I'm now happy to reattach the seat latch area, do that patch on the right side, add whatever reinforcing is needed, and finish the trimming.

Just a pity I don't have more time where I can make some noise, trimming by hand at night with the hacksaw is a PITA.
 
Reattached the seat latch area last night, just enough to hold it in place so I can double check the location is right before making it nice and secure and reinforcing it.



And I repaired the tear (left side of the photo) and added some reinforcing in the same area on the other side just to be sure, although it didn't tear and doesn't look like tearing.

Just realised I didn't get a pic of the prep work, but the tear had gone in a Y shape so I drilled a small hole at each end of the tear, then a few more along the lengths of it. I sanded it all back with 60 grit which showed up a weak line where the different bits of matting joined, so I trimmed that out with a hacksaw.

I then filled that weak line up with two layers of matting, then two layers on the back side and another layer on the front side, so it should be nice and strong now.





Once they've hardened up I can test fit the seat with the seat latch and make sure the location is right, then I can properly reinforce the seat latch area and get the seat trimmed down to the right size.

I'm waiting to trim the front until I get the tank mounting rubbers from Mick Hone. Ordered them on Tuesday with Express Post but they still hadn't arrived yesterday so I'll have to chase that up today. We've had a few parcels delayed lately... good ol' Aussie Post...
 
Things have been looking pretty good with the seat.

Got some holes drilled to take the stock rubber cushions for the frame:



Trimming down the front is getting close and it was locating with the seat latch pretty nicely:



Shaping up with the tail piece was looking good:



But put it all together and it's 5 to 10mm's too long... ugh:



Going to have to trim the very rear off and then work out where to go from there... so damn close! This is kickin' my butt hard...
 
cut and splice.

Cut out a 10mm piece in the centre and just rejoin it! Thats the luxury and simplness of fiberglass!
 
Fjbj40 said:
cut and splice.

Cut out a 10mm piece in the centre and just rejoin it! Thats the luxury and simplness of fiberglass!
Click to expand...

I agree. Take what you need out of the middle, 'glass it back together and leave the trailing end the way it is. Way simpler, Pete. The trials and tribulations of customizing, eh,,?
 
If it were me, First I'd try the belt sander to the back of it, little by little (hand fitting between sanding).
Otherwise how do you know the latches will still line up right?
Seems like the easiest way. Can't tell by pics exactly.
Hopefully much less than 10mm needs removed...maybe it swelled up curing or such?
Good work , great bike too!

EDIT: Just draw the line on back with a thick marker and observe it while sanding,check whether enough often, is what I'd do. first anyway.
 
Last edited:
I think I like the cut and shut idea the best, cheers guys!

It should be a lot simpler than taking anything off the rear as long as I'm careful and ensure the cut is nice and straight and even.

Hopefully I can get motivated to get out there tonight and get moving on it, motivation was seriously lacking last night after seeing that...

And yep Larry, trials and tribulations alright! Surely I've gotta have some success sometime soon with this!
 
Half the fun is the learning process, Pete. Look how far you've come since your 450. You're doing excellent work. I always look forward to the progress.
 
Pete, no doubt motivation can sometimes be hard to find but myself and am sure many others following this thread are impressed with your "sticktoitiveness".
 
Cheers guys! There are times when you seem to always be 1 step forwards 2 steps back and this has been one of them with the seat. I'll keep persevering because I know once it's done it opens up a whole new avenue of progress moving towards getting a roller done.

I got the pillion area cut in half and sat the rear part on to measure the difference at the top, 8mm seemed a good number.



Sat back in place after removing the 8mm and looks good to me.



Got the two parts as level and stable as I could and they seemed to line up well, so two layers underneath to start with to get them joined.



Hopefully I'll be able to give it a test fit tonight and if it looks good I'll add another layer on the top side and add the reinforcing to the seat latch area.

If this all works out I'll be pretty close to done...
 
On the left side yes... I need to sort that. Sorry, forgot to say the left rear bit bulges out a little, must'nt have flattened it against the mould as much as the right side or something... the right side has more of a gap to the tail piece. It's easy fixed, just haven't gotten there yet.
 
Had a bunch of delays lately between fixing the plumbing under the kitchen sink and stupid hours at work, but I'm finally to the point where all it needs is a final tidy up.

I've got the day off on Monday and will be taking it down to the upholsterer to get it done.





Then I'm going to hit another delay... I've gotta get the 450 on single seat rego by the time it's due in December. Taking a shortcut on this one and using a seat pan I got from eBay, so it should be relatively quick although it needs some repairs... think I'll still be pushing the proverbial uphill with a rake to get it done on time.
 
pete said:
Then I'm going to hit another delay... I've gotta get the 450 on single seat rego by the time it's due in December. Taking a shortcut on this one and using a seat pan I got from eBay, so it should be relatively quick although it needs some repairs... think I'll still be pushing the proverbial uphill with a rake to get it done on time.
Click to expand...

You should try using a pointed stick.
 
tatu said:
You should try using a pointed stick.
Click to expand...

Hahaha yes! Good suggestion, will take that on board...

Seat will be a couple of weeks, hopefully enough time to swap with him for the 450's seat.
 
So after watching the birthing process of this fiberglass pan with interest I have to admit I have one question. What stopped you from doing something like wrapping the rear portion of the foam with a fiberglass shell then reupholstering it as such? The pillion area would still be solid to an inspector but with far less hassle.
 
Definitely a valid question! There are three good reasons though ;)... first I didn't want to mess around with the existing seat as the foam is in pretty good shape and it can be used again.

Second, there's at least one other guy who may want me to do one for them (I owe him for a bunch of bits like the fuel tank).

Third, I wanted extra room under that pillion area for storage.

But for anyone else who wants to maintain their sanity and get the job done in a reasonable amount of time, definitely modify a stock pan :D
 
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