-
Required reading for all forum users!!!
Welcome!
Register to access the full functionality of the GSResources forum. Until you register and activate your account you will not have full forum access, nor will you be able to post or reply to messages.A note to new registrants...
All new forum registrations must be activated via email before you have full access to the forum.A Special Note about Email accounts!
DO NOT SIGN UP USING hotmail, outlook, gmx, sbcglobal, att, bellsouth or email.com. They delete our forum signup emails.A note to old forum members...
I receive numerous requests from people who can no longer log in because their accounts were deleted. As mentioned in the forum FAQ, user accounts are deleted if you haven't logged in for the past 6 months. If you can't log in, then create a new forum account. If you don't get an error message, then check your email account for an activation message. If you get a message stating that the email address is already in use, then your account still exists so follow the instructions in the forum FAQ for resetting your password.Have you forgotten your password or have a new email address? Then read the forum FAQ for details on how to reset it.
Any email requests for "can't log in anymore" problems or "lost my password" problems will be deleted. Read the forum FAQ and follow the instructions there - that's what we have one for...
-
Returning Visitors
If you are a returning visitor who never received your confirmation email, then odds are your email provider is blockinig emails from our server. The only thing that can be done to get around this is you will have to try creating another forum account using an email address from another domain.
If you are a returning visitor to the forum and can't log in using your old forum name and password but used to be able to then chances are your account is deleted. Purges of the databases are done regularly. You will have to create a new forum account and you should be all set.
G
Guest
Guest
Ok cool cheers Daryl and Larry, think I'm all set now!
Nice to have you along for the ride Charlie
I hope to get back into the sanding today but will likely finish it up tomorrow as it's supposed to be a bit wet. Wednesday should be a good day for the next lot of high build to get laid down.
Yesterday was occupied getting the Kat its new home in the garage, no more sitting outside under a cover. The old Festiva is getting put out to pasture later this week so there's going to be a lot more room in the garage later today. Excuse the mess, still a lot to sort out, but it's exciting having both bikes in side by side
Untitled by starpoint73, on Flickr
Nice to have you along for the ride Charlie
I hope to get back into the sanding today but will likely finish it up tomorrow as it's supposed to be a bit wet. Wednesday should be a good day for the next lot of high build to get laid down.
Yesterday was occupied getting the Kat its new home in the garage, no more sitting outside under a cover. The old Festiva is getting put out to pasture later this week so there's going to be a lot more room in the garage later today. Excuse the mess, still a lot to sort out, but it's exciting having both bikes in side by side
Untitled by starpoint73, on Flickr
G
Guest
Guest
I got a bit more sanding done than I hoped yesterday, probably about 50% there.
Definitely need more high build primer.
There are a couple of spots on the tail piece that may need something more substantial like some blade putty, and the spot I had to plastic weld on the rear of the front mudguard will likely need that as well. They're a touch more than just a low spot.
Aside from those spots, looking good!
Untitled by starpoint73, on Flickr
Untitled by starpoint73, on Flickr
Definitely need more high build primer.
There are a couple of spots on the tail piece that may need something more substantial like some blade putty, and the spot I had to plastic weld on the rear of the front mudguard will likely need that as well. They're a touch more than just a low spot.
Aside from those spots, looking good!
Untitled by starpoint73, on FlickrUntitled by starpoint73, on Flickr
nvr2old
Forum Sage
Lookin' good, Pete. Sand, sand, and when you get tired of sanding..sand some more. 
From what I can see in your pics, your guide coat is doing exactly what it should be doing. Don't be afraid to sand it with the 180 till you hit plastic filler again. Sometimes that's necessary to get it down as far as it needs to go, plus it keeps the build-up to a minimum. If you go that far and there are still a few pinholes or what not, maybe use a bit more filler. Your second round of primer will do wonders. Your parts are coming along very nicely. You'll be really happy with the results. I can already tell.
From what I can see in your pics, your guide coat is doing exactly what it should be doing. Don't be afraid to sand it with the 180 till you hit plastic filler again. Sometimes that's necessary to get it down as far as it needs to go, plus it keeps the build-up to a minimum. If you go that far and there are still a few pinholes or what not, maybe use a bit more filler. Your second round of primer will do wonders. Your parts are coming along very nicely. You'll be really happy with the results. I can already tell.
G
Guest
Guest
Cheers Larry, yep definitely happy with how things are looking!
All sanded ready to go for the next lot of high build primer. I gave them a real good wash down with the hose but tomorrow I'll give them a go over with high pressure air then wax and grease remover.
I had to go through to the fibreglass and plastic in places but it's all nice and smooth, but definitely needs another go round.
I did find some big pits and divets I'd managed to miss on all three pieces, so I did add a little body filler in a few places to fix those up. You can see one spot on the mudguard there.
Untitled by starpoint73, on Flickr
The side covers are pretty much ready for primer so if tomorrow works out I'll try to prime those as well. I should've finished sanding them today but I forgot all about them.
Fingers crossed the weather's good for it tomorrow, today's "shower or two" turned into a storm with torrential rain.
All sanded ready to go for the next lot of high build primer. I gave them a real good wash down with the hose but tomorrow I'll give them a go over with high pressure air then wax and grease remover.
I had to go through to the fibreglass and plastic in places but it's all nice and smooth, but definitely needs another go round.
I did find some big pits and divets I'd managed to miss on all three pieces, so I did add a little body filler in a few places to fix those up. You can see one spot on the mudguard there.
Untitled by starpoint73, on FlickrThe side covers are pretty much ready for primer so if tomorrow works out I'll try to prime those as well. I should've finished sanding them today but I forgot all about them.
Fingers crossed the weather's good for it tomorrow, today's "shower or two" turned into a storm with torrential rain.
Man, there's way more to paint than I thought... Learning a lot here.
nvr2old
Forum Sage
That's a common thought for most people, Sam, who've never seen or gone through the correct process. There's a lot involved in a quality paint job. Prep and finish work are 90% of it. Material and labor costs can get pretty expensive to have it done by a pro, but the results usually speak for themselves. Pete's doing a great job.
G
Guest
Guest
Yep, my admiration for guys like Larry who do superb paint jobs has escalated enormously since I did my 450, and is increasing even more this second time around.
I'm still taking a bit of a shortcut by not bothering about what the inside of the parts look like, or under the front mudguard (although I did give them a clean at least), but the time spent making the parts right as a base for the paint is time well spent.
The painting really is the easy bit as long as you know how to set the gun up right (which I learnt from the very helpful fellas on here last time 'round).
The prep work is really where it's at, and it really is worth putting the extra time and effort into it, the paint really won't mask poor prep work.
The same goes for aerosol jobs too, not just 2K applications. I've learnt that the hard way also
And cheers Larry! I'm keen to make this a good job for sure.
Humidity right now is a little higher than it should be but forecast to drop, so fingers crossed by the time I get the side covers prep'd and everything cleaned down it'll be low enough to get that second lot of primer done.
I'm still taking a bit of a shortcut by not bothering about what the inside of the parts look like, or under the front mudguard (although I did give them a clean at least), but the time spent making the parts right as a base for the paint is time well spent.
The painting really is the easy bit as long as you know how to set the gun up right (which I learnt from the very helpful fellas on here last time 'round).
The prep work is really where it's at, and it really is worth putting the extra time and effort into it, the paint really won't mask poor prep work.
The same goes for aerosol jobs too, not just 2K applications. I've learnt that the hard way also
And cheers Larry! I'm keen to make this a good job for sure.
Humidity right now is a little higher than it should be but forecast to drop, so fingers crossed by the time I get the side covers prep'd and everything cleaned down it'll be low enough to get that second lot of primer done.
nvr2old
Forum Sage
G
Guest
Guest
Well... the sidecovers and front mudguard will be ok the way they are (already pretty tidy to my mind) but the front cowl and tail piece are a different story. I'll see if I can get motivated to mask all the fresh paint off once they're done and squirt some satin in there. Pretty sure I have enough of a can of it left in the shed actually.
I got the second round of high build primer done today including the side covers and choke lever.
I definitely noticed some little pits and things though, so it all definitely needs another good sanding. I noticed some bits show up on the side covers so I'm glad they got the high build as well.
Untitled by starpoint73, on Flickr
I also made a decent run on the tail piece just below this nice big divet I found... not sure what the deal is with that! Might have to brush a little primer on it or something then rub it back.
Untitled by starpoint73, on Flickr
It's all had a guide coat applied as well.
While moving the crankcases during the garage clean up I got reminded of an issue I need to fix in the stator area of the top case. It looked like a bit of a dodgy repair to me.
Untitled by starpoint73, on Flickr
So tonight I broke out the files and got stuck in.
I have no idea what was used but it's way too brittle and flaky to be JB Weld and it just came off real easy without too much effort with the files. The gasket surface part of the repair was extremely uneven and there's no way that would be oil tight without a bunch of gasket goo or something.
It needs a go over with a dremel to clean it up properly but I'll have to wait for daytime when I can make some noise to do that.
Anyone got some photos of this area I can use as a reference when building it up properly with JB Weld? Need to get myself a stator cover to help with that too! There's one on eBay I'm eyeing off, I need a GSX1100 rather than a Kat one as I have the larger GSX type stator/rotor setup.
Untitled by starpoint73, on Flickr
Untitled by starpoint73, on Flickr
I got the second round of high build primer done today including the side covers and choke lever.
I definitely noticed some little pits and things though, so it all definitely needs another good sanding. I noticed some bits show up on the side covers so I'm glad they got the high build as well.
Untitled by starpoint73, on FlickrI also made a decent run on the tail piece just below this nice big divet I found... not sure what the deal is with that! Might have to brush a little primer on it or something then rub it back.
Untitled by starpoint73, on FlickrIt's all had a guide coat applied as well.
While moving the crankcases during the garage clean up I got reminded of an issue I need to fix in the stator area of the top case. It looked like a bit of a dodgy repair to me.
Untitled by starpoint73, on FlickrSo tonight I broke out the files and got stuck in.
I have no idea what was used but it's way too brittle and flaky to be JB Weld and it just came off real easy without too much effort with the files. The gasket surface part of the repair was extremely uneven and there's no way that would be oil tight without a bunch of gasket goo or something.
It needs a go over with a dremel to clean it up properly but I'll have to wait for daytime when I can make some noise to do that.
Anyone got some photos of this area I can use as a reference when building it up properly with JB Weld? Need to get myself a stator cover to help with that too! There's one on eBay I'm eyeing off, I need a GSX1100 rather than a Kat one as I have the larger GSX type stator/rotor setup.
Untitled by starpoint73, on FlickrUntitled by starpoint73, on Flickr
nvr2old
Forum Sage
The parts look great after the 2nd prime. Cut your runs out with some 180, Pete, then go to 400. It'll be way easier. You might try mixing up a small amount of plastic filler and forcefully pushing it into that pinhole with your finger. That should take care of it.
I've fixed an area like that on your engine with JB Weld before, too. Even re-made, drilled and re-threaded a mounting boss. Such a versatile product.
I've fixed an area like that on your engine with JB Weld before, too. Even re-made, drilled and re-threaded a mounting boss. Such a versatile product.
G
Guest
Guest
Cheers Larry, yeah generally they're looking great, just that one spot on the tail piece and a couple of spots on the cowl I'm not 100% happy with. Might be a good spot to use a touch of that blade putty I tried earlier as it's real easy to work and should sit in those little holes very well.
Stupid question time... once it's all sanded back and smooth, I still need a go over with the primer as a surfacer prior to the base colour coat right? I'm mainly thinking of colour coat over the putty or filler not being a great idea. Then sand with the 600 ready for colour.
I remember the JB on your CB cooling fin I'm pretty sure it was? It's good stuff alright! I did that mounting post in the rear master cylinder reservoir earlier in this build.
I figure the same idea with some scrap aluminium coated in anti seize to form the inside curve of the repair should make it a much neater end result than what was there. I'll just make sure to build it up above the gasket surface, file it back close, then finish off with sandpaper so it's smooth and oil tight to match with the rest of the gasket surface.
Just need my hands on a stator cover to match the outside shape up neatly and I'm hoping one of the Katana folk or someone with an 1100 can snap some pic's of the area so I can hopefully get it close to looking how it should.
Stupid question time... once it's all sanded back and smooth, I still need a go over with the primer as a surfacer prior to the base colour coat right? I'm mainly thinking of colour coat over the putty or filler not being a great idea. Then sand with the 600 ready for colour.
I remember the JB on your CB cooling fin I'm pretty sure it was? It's good stuff alright! I did that mounting post in the rear master cylinder reservoir earlier in this build.
I figure the same idea with some scrap aluminium coated in anti seize to form the inside curve of the repair should make it a much neater end result than what was there. I'll just make sure to build it up above the gasket surface, file it back close, then finish off with sandpaper so it's smooth and oil tight to match with the rest of the gasket surface.
Just need my hands on a stator cover to match the outside shape up neatly and I'm hoping one of the Katana folk or someone with an 1100 can snap some pic's of the area so I can hopefully get it close to looking how it should.
nvr2old
Forum Sage
G
Guest
Guest
Cool cheers Larry, makes good sense. I do know how I got that run on there, easily avoided again. Basically I stopped paying attention mid spray and leaned in too close... easy not to repeat!
I'm hoping I can get started on some sanding later today, but the weather's not looking great for my ride tomorrow nor getting the paint done next week, forecast is definitely looking dodgy for painting.
I'm hoping I can get started on some sanding later today, but the weather's not looking great for my ride tomorrow nor getting the paint done next week, forecast is definitely looking dodgy for painting.
G
Guest
Guest
Man I'm so over sanding... found lots more pinpricks and low spots again today and had to resort to body filler in places as I was going through the primer again.
I've still got a few areas on the front cowl to finish sanding in the morning but fingers crossed the next lot of primer will end up all set for the colour coats.
I decided to give myself a little distraction tonight and throw all the bodywork on the Kat with the new tank and have a double check for fitment. Nothing bolted or screwed so they're not all sitting quite right but looks good to me. Excuse the mess, still a bit to sort out in the garage yet.
Untitled by starpoint73, on Flickr
Untitled by starpoint73, on Flickr
On the downside, I did discover an issue where the fibreglass around the top mounting hole for the front cowl has cracked. Not sure how I didn't find this earlier, very frustrating!
Untitled by starpoint73, on Flickr
The only thing I can think of doing is sand it right back underneath to bare fiberglass so I can add a layer of matting to it. I can't build it up any higher as that will lift the front of the cowl up too much and interfere with the headlight.
Of course that will put paid to any chance of getting the next round of primer on tomorrow, although the forecast isn't all that brilliant for painting anyway.
However, I'd rather find that now so I can fix it before the colour goes on... I'd be a bit peeved if I saw that crack the gloss black and clear when I mounted it!
I've still got a few areas on the front cowl to finish sanding in the morning but fingers crossed the next lot of primer will end up all set for the colour coats.
I decided to give myself a little distraction tonight and throw all the bodywork on the Kat with the new tank and have a double check for fitment. Nothing bolted or screwed so they're not all sitting quite right but looks good to me. Excuse the mess, still a bit to sort out in the garage yet.
Untitled by starpoint73, on FlickrUntitled by starpoint73, on FlickrOn the downside, I did discover an issue where the fibreglass around the top mounting hole for the front cowl has cracked. Not sure how I didn't find this earlier, very frustrating!
Untitled by starpoint73, on FlickrThe only thing I can think of doing is sand it right back underneath to bare fiberglass so I can add a layer of matting to it. I can't build it up any higher as that will lift the front of the cowl up too much and interfere with the headlight.
Of course that will put paid to any chance of getting the next round of primer on tomorrow, although the forecast isn't all that brilliant for painting anyway.
However, I'd rather find that now so I can fix it before the colour goes on... I'd be a bit peeved if I saw that crack the gloss black and clear when I mounted it!
A mock-up always lifts the spirits.
btw, your garage isn't even close to being messy. haha.
btw, your garage isn't even close to being messy. haha.
nvr2old
Forum Sage
Always a pain to have to go backwards, for sure. Better now then later, though as you mentioned. I think you have the right idea about the crack, Pete. Build it up a bit underneath to strengthen that area. If you have a Dremel tool, maybe just surgically V out the upper crack, chop up some fiberglass mat into a fine little pile in a mixing cup, add the catalyst/hardener directly to it, stir it together and force as little as necessary into the groove to fill it up. Sand, a bit of plastic filler if needed and re-prime. From the looks of the fairing it's gonna need another round, too..so no biggee, sometimes that's just the way it goes. Just keep telling yourself how nice the final results from all your work will be.
G
Guest
Guest
Haha cheers Steve it sure does! Well, the garage is a lot tidier than it was that's for sure... it's getting easier to sort now I have a lot more room with one less car in there!
And cheers Larry, I was hoping not to touch the top surface if I can avoid it but I'll see how it goes after I sand back underneath to the source of the troubles.
As it is now the cowl actually does seem to sit a little high as there's more of a gap at the top of the headlight than the bottom, but after looking at as many Kats as possible it seems probably 50% of cowls aren't even around the headlight, so I didn't think it was an issue. That's the other bright side with this crack I guess... it's an opportunity to make it sit a little more level.
After looking at what I had to do to the cowl to try to get those low spots gone yesterday, I wouldn't be surprised in the slightest if it does indeed need another round of primer, see how it goes. If I get cracking early enough this morning I still may get the next lot of primer done today, the weather is not what they were predicting (again).
And cheers Larry, I was hoping not to touch the top surface if I can avoid it but I'll see how it goes after I sand back underneath to the source of the troubles.
As it is now the cowl actually does seem to sit a little high as there's more of a gap at the top of the headlight than the bottom, but after looking at as many Kats as possible it seems probably 50% of cowls aren't even around the headlight, so I didn't think it was an issue. That's the other bright side with this crack I guess... it's an opportunity to make it sit a little more level.
After looking at what I had to do to the cowl to try to get those low spots gone yesterday, I wouldn't be surprised in the slightest if it does indeed need another round of primer, see how it goes. If I get cracking early enough this morning I still may get the next lot of primer done today, the weather is not what they were predicting (again).
G
Guest
Guest
I quite surprised myself by getting up nice and early this morning. Early enough to not only finish sanding the front cowl and repair the cracked mounting hole, but also to get the next lot of primer done. I was even more surprised the weather was decent enough to paint!
I broke out the 80 grit wet and dry and took as much material from underneath the cracked area as I could to make sure the repair didn't lift the cowl up.
Looks like I simply found someone else's dodgy repair. I think that area had been damaged previously as what was revealed appears to be a circular piece of body filler that was painted over with no reinforcing.
It could actually be removed from the hole...
Untitled by starpoint73, on Flickr
Untitled by starpoint73, on Flickr
Anyway, best I could think of was to put two layers of fibreglass underneath for a proper repair but keep that bit of body filler so I didn't lose the hole location.
I managed to get enough sun on it and went a bit heavy on the MEKP so the resin cured nice and quick so I was able to get the top sanded back nicely with a touch up of filler around the cracked area.
Untitled by starpoint73, on Flickr
Untitled by starpoint73, on Flickr
While I didn't test mount it again I did put a fair amount of pressure from underneath and all that happened was the top flexed, which is what I was hoping for.
Then I got done with hopefully the last round of primer, although the front cowl of course is the big question mark. Everything got three coats but I had enough to give the cowl a fourth which I hope helps.
I decided to be brave/stupid/optimistic (take your pick) and not do a guide coat this time around. I'm pretty confident the front guard, tail piece, and side covers are good with just a rub back with 600, but the front cowl still seems to have a few pin pricks on the left side, just have to see how deep they are with the 400 first before deciding if it will need a final go with primer or not.
Untitled by starpoint73, on Flickr
Untitled by starpoint73, on Flickr
Untitled by starpoint73, on Flickr
Untitled by starpoint73, on Flickr
Untitled by starpoint73, on Flickr
I broke out the 80 grit wet and dry and took as much material from underneath the cracked area as I could to make sure the repair didn't lift the cowl up.
Looks like I simply found someone else's dodgy repair. I think that area had been damaged previously as what was revealed appears to be a circular piece of body filler that was painted over with no reinforcing.
It could actually be removed from the hole...
Untitled by starpoint73, on FlickrUntitled by starpoint73, on FlickrAnyway, best I could think of was to put two layers of fibreglass underneath for a proper repair but keep that bit of body filler so I didn't lose the hole location.
I managed to get enough sun on it and went a bit heavy on the MEKP so the resin cured nice and quick so I was able to get the top sanded back nicely with a touch up of filler around the cracked area.
Untitled by starpoint73, on FlickrUntitled by starpoint73, on FlickrWhile I didn't test mount it again I did put a fair amount of pressure from underneath and all that happened was the top flexed, which is what I was hoping for.
Then I got done with hopefully the last round of primer, although the front cowl of course is the big question mark. Everything got three coats but I had enough to give the cowl a fourth which I hope helps.
I decided to be brave/stupid/optimistic (take your pick) and not do a guide coat this time around. I'm pretty confident the front guard, tail piece, and side covers are good with just a rub back with 600, but the front cowl still seems to have a few pin pricks on the left side, just have to see how deep they are with the 400 first before deciding if it will need a final go with primer or not.
Untitled by starpoint73, on FlickrUntitled by starpoint73, on FlickrUntitled by starpoint73, on FlickrUntitled by starpoint73, on FlickrUntitled by starpoint73, on Flickr
nvr2old
Forum Sage
That's funny to find out, Pete. I was thinking.."that crack is so perfectly round it almost looks like there might be a washer in there..but surely.." Nice job on the repair. Everything looks real good. I know you're probably sick of sanding by this time (who wouldn't be) but just spritz it with guide coat, though. You'll be surprised how much it reveals even at this stage especially the fairing. I've worked with guys that would use guide coat on the final clear coat and saw the results speaking for themselves. Give yerself a mighty pat on the back, Pete, it's gonna look nice.
