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1981 GSX1100 Katana Based Project

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    Originally posted by Blower View Post

    Are you sure the aluminum spacer tube won't collapse when you tighten the pivot bolt to torque?​
    I would like to think it will be O.K. but until it has been in use and fully tested it is a bit of the unknow right now. The spacer would be difficult to damage because to crush the spacer the frame and swing-arm would need to be distorted when setting the torque on the pivot bolt, an unlikely event. I am not worried if it does suffer damage when in use, sometimes new and untested things work and sometimes they don't. If needed I would just make another one with slightly thicker walls and perhaps smaller bore holes.
    Last edited by Shin-Ken 1074; 10-29-2023, 09:26 PM.
    Badgezz, we don need noh stinkin' badgezz!
    Shin-Ken 1074
    1982 GSX1100SXZ Wire Wheel Katana - BOM Nov 2011
    1981 GSX1135 Katana Build completed Mar 2024, Curb Weight, all fluids and 21 lt fuel = 206 kg.

    Comment


      I wasn't happy with the carbon screen I made and how heavy it turned out to be. The first couple of screens I made were O.K. but went in the reject pile for various reasons. The weight of the carbon screen for the DW 180 has been bugging me for the last week so I had to do something about it. I have picked out the best of the reject screens I made and will use it for the DW 180. At 99 grams it is 1/3 lighter without the trim fitted and will polish up O.K. for use.

      Carbon screen MKII b by Max Mutarn, on Flickr



      Carbon screen MKII c by Max Mutarn, on Flickr
      Last edited by Shin-Ken 1074; 10-31-2023, 02:27 AM.
      Badgezz, we don need noh stinkin' badgezz!
      Shin-Ken 1074
      1982 GSX1100SXZ Wire Wheel Katana - BOM Nov 2011
      1981 GSX1135 Katana Build completed Mar 2024, Curb Weight, all fluids and 21 lt fuel = 206 kg.

      Comment


        The best of the reject screens is now the MK II screen for the project. Polished and ready to go and at 99 grams I am happy with it.

        Carbon screen polish by Max Mutarn, on Flickr


        Carbon screen MKII by Max Mutarn, on Flickr
        Badgezz, we don need noh stinkin' badgezz!
        Shin-Ken 1074
        1982 GSX1100SXZ Wire Wheel Katana - BOM Nov 2011
        1981 GSX1135 Katana Build completed Mar 2024, Curb Weight, all fluids and 21 lt fuel = 206 kg.

        Comment


          Now with new oil and seals the forks are ready to go on. TNK refurbished clocks with the top plate before fitting the forks. TNK clocks are the same weight as OEM clocks because they are OEM clocks with a TNK dial, just with a different look using the white dial.

          TNK clocks by Max Mutarn, on Flickr

          Badgezz, we don need noh stinkin' badgezz!
          Shin-Ken 1074
          1982 GSX1100SXZ Wire Wheel Katana - BOM Nov 2011
          1981 GSX1135 Katana Build completed Mar 2024, Curb Weight, all fluids and 21 lt fuel = 206 kg.

          Comment


            Got carbon fibre ??

            カタナに次々盛り込む驚異的アップデート 「最新の変更点はドライカーボン製タンクへの換装と角度可変スクリーン、そ ...


            186kg

            Comment


              What an epic build!
              Blows my mind the amount of weight you already saved!
              Compliments!!!
              "All out till you see God, then brake" (Kevin Schwantz)

              GSXR1000K1 - Katana GSX1216SR Turbo - 2x Katana GSX1100SZ - Katana GSX750S - Harris Magnum2 GS1000 - Harris Magnum4 GSX-R1201 - Nico Bakker GS1085 - JMC GSXR1216 - MotoMartin GSX1100 - UPSSR750R - GSXR1216M - GSXR1255J Yoshimura - GSXR1100J - GSXR1100W - GSX1260ET - 2x GSX1100ET - 3x GSX1100EF - 2x GS1000SN - GS1000ET Wil Hartog - GS1000E - GS1000C - GS750R - GSX1100F - KTM1190 Adventure​

              Comment


                I really like the look of the white background on the gauges.
                2@ \'78 GS1000

                Comment


                  Originally posted by GSX1100 dreamn View Post
                  Got carbon fibre ??

                  カタナに次々盛り込む驚異的アップデート 「最新の変更点はドライカーボン製タンクへの換装と角度可変スクリーン、そ ...


                  186kg
                  Yeah, a very trick custom Kat, 186 kg eh?
                  Badgezz, we don need noh stinkin' badgezz!
                  Shin-Ken 1074
                  1982 GSX1100SXZ Wire Wheel Katana - BOM Nov 2011
                  1981 GSX1135 Katana Build completed Mar 2024, Curb Weight, all fluids and 21 lt fuel = 206 kg.

                  Comment


                    Originally posted by Jero+ View Post
                    What an epic build!
                    Blows my mind the amount of weight you already saved!
                    Compliments!!!
                    Thank you Jero+, got a bit more done today.

                    Cheers.
                    Badgezz, we don need noh stinkin' badgezz!
                    Shin-Ken 1074
                    1982 GSX1100SXZ Wire Wheel Katana - BOM Nov 2011
                    1981 GSX1135 Katana Build completed Mar 2024, Curb Weight, all fluids and 21 lt fuel = 206 kg.

                    Comment


                      Originally posted by steve murdoch View Post
                      I really like the look of the white background on the gauges.
                      Hi Steve, Yes, the white dial gives it a fresh look, I like it a lot!

                      Cheers.
                      Badgezz, we don need noh stinkin' badgezz!
                      Shin-Ken 1074
                      1982 GSX1100SXZ Wire Wheel Katana - BOM Nov 2011
                      1981 GSX1135 Katana Build completed Mar 2024, Curb Weight, all fluids and 21 lt fuel = 206 kg.

                      Comment


                        Front wheel, clocks and forks today. Revised front wheel weight, complete wheel assembly is now 12,950 grams.

                        DW complete F wheel by Max Mutarn, on Flickr


                        Clock fork wheel 1 by Max Mutarn, on Flickr


                        Clocks by Max Mutarn, on Flickr


                        Clocks and ignition = 1055 g.

                        Forks = 8,680 g.

                        Brace = 378 g.

                        Front wheel weight = 12,950.


                        Running tally = 147,452 grams.
                        Last edited by Shin-Ken 1074; 11-03-2023, 12:45 AM.
                        Badgezz, we don need noh stinkin' badgezz!
                        Shin-Ken 1074
                        1982 GSX1100SXZ Wire Wheel Katana - BOM Nov 2011
                        1981 GSX1135 Katana Build completed Mar 2024, Curb Weight, all fluids and 21 lt fuel = 206 kg.

                        Comment


                          I don't think the oil filter cover needs to have more fins than a shark party. Shaved a few grams from the cover and now looks a bit sporty compared to the OEM design.

                          OEM cover = 227 grams.
                          OEM cover by Max Mutarn, on Flickr


                          Shaved oil cover
                          Shaved cover by Max Mutarn, on Flickr


                          Oil cover, Ti nuts, filter, O-ring gasket filter spring.
                          DW 180 cover by Max Mutarn, on Flickr
                          Badgezz, we don need noh stinkin' badgezz!
                          Shin-Ken 1074
                          1982 GSX1100SXZ Wire Wheel Katana - BOM Nov 2011
                          1981 GSX1135 Katana Build completed Mar 2024, Curb Weight, all fluids and 21 lt fuel = 206 kg.

                          Comment


                            Lightened the engine by a few grams today. When the engine was weighed it was fitted with the stock five OEM steel oil gallery bolts that weigh 29 grams each. There are 3 other oil bolts, two in the front of the block for the oil cooler lines and the sump plug. The oil cooler bolts are an issue for another day however, the sump plug has been replaced with one of the hollow ally bolts as well. The sump has not been installed yet so that bolt is not included in the running tally today.

                            In total the five hollow aluminium bolts weigh 1 gram more than just one of the OEM steel bolts!


                            OEM oil bolt 2 by Max Mutarn, on Flickr

                            OEM oil bolt by Max Mutarn, on Flickr


                            Replacing the steel bolts with hollow aluminium that weigh 6 grams each.
                            DW oil bolt by Max Mutarn, on Flickr

                            DW oil bolt 2 by Max Mutarn, on Flickr

                            5 x OEM oil bolts = 145 grams.

                            5 x hollow ally oil bolts = 30 grams.

                            147,452 g - 115 g = 147,337 g.

                            Running tally = 147,337 g.
                            Last edited by Shin-Ken 1074; 11-03-2023, 12:46 AM.
                            Badgezz, we don need noh stinkin' badgezz!
                            Shin-Ken 1074
                            1982 GSX1100SXZ Wire Wheel Katana - BOM Nov 2011
                            1981 GSX1135 Katana Build completed Mar 2024, Curb Weight, all fluids and 21 lt fuel = 206 kg.

                            Comment


                              Stator and cover installed today, total weight including Ti bolts = 1,733 g.


                              EF Stator by Max Mutarn, on Flickr


                              Running tally = 149,070 grams.
                              Badgezz, we don need noh stinkin' badgezz!
                              Shin-Ken 1074
                              1982 GSX1100SXZ Wire Wheel Katana - BOM Nov 2011
                              1981 GSX1135 Katana Build completed Mar 2024, Curb Weight, all fluids and 21 lt fuel = 206 kg.

                              Comment


                                You'll have to chain this bike down at night. Else it'll just float away.
                                1982 GS1100E V&H "SS" exhaust, APE pods, 1150 oil cooler, 140 speedo, 99.3 rear wheel HP, black engine, '83 red

                                2016 XL883L sigpic Two-tone blue and white. Almost 42 hp! Status: destroyed, now owned by the insurance company. The hole in my memory starts an hour before the accident and ends 24 hours after.

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