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1981 GSX1100 Katana Based Project

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    #61
    Originally posted by Shin-Ken 1074 View Post

    Hi Rob,

    the Kat front guard has a U shaped pressed steel brace that sits inside the front guard and bolted to each fork leg. Without the four bolts/washers it weighs 800 grams. The rear sub-frame I have removed is the steel frame that secures the inner rear guard to the main frame, without bolts/washers = 260 grams.

    Cheers.
    The mudguard inside brace is actually a fork brace and so you might want something up there.
    1979 gs1000e (everyday) 1977 gs750 for sale
    1983 yam xj550 maxim streetbob sold
    1995 gsx750F everyday fighterjet 1990 gsx1100F for sale
    2000kaw zx600
    2003 BMW K1200GT sport tour
    2000Buel Cyclone M2 motorwork
    1984 Yam venture xvz1200 -long ride/cold ride ride gf ride..
    1978 Honda cb750F3 supersport top end (still)
    1976 Harley FL 3/8" S&S stroker - motor out way too long
    1980 Harley fxs80 - wacked good on this one

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      #62
      What's the current weight and running status? I must admit, at first I thought this was a pipe dream, but you seem to know what you are doing. However...

      If it turns out that you personally weigh 400 lbs, a lot of us are going to be disappointed!
      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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        #63
        Been following along quietly with interest. Not sure if you have the wheels in hand yet, but mid 90s Triumph Trident wheels look suspiciously similar to later model GS wheels, but in modern sizes and likely lighter. There'd probably be some modifications involved with the brakes though. It's something I'd like to try someday.
        sigpic
        When consulting the magic 8 ball for advice, one must first ask it "will your answers be accurate?"

        Glen
        -85 1150 es - Plus size supermodel.
        -Rusty old scooter.
        Other things I like to photograph.....instagram.com/gs_junkie
        https://www.instagram.com/glen_brenner/
        https://www.flickr.com/photos/152267...7713345317771/

        Comment


          #64
          Originally posted by Rob S. View Post
          What's the current weight and running status? I must admit, at first I thought this was a pipe dream, but you seem to know what you are doing. However...

          If it turns out that you personally weigh 400 lbs, a lot of us are going to be disappointed!
          v
          Hi Rob, sorry for the delayed reply, a very close friend passed away last week and have been involved with other matters, so the Kat project and logging on the Forum has taken a back seat for the last week or so.

          Buddy if I weighted 400lbs I would be very disappointed as well, I do carry a few kg more than I should be for someone over 60, but only a few kgs.

          Will post an update tonight my time. Dropped off the aluminium axle spacers today to be anodised and should have them back in 10 days.


          Cheers,
          Glen.
          Last edited by Shin-Ken 1074; 09-25-2023, 04:32 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


            #65
            Originally posted by dorkburger View Post
            Been following along quietly with interest. Not sure if you have the wheels in hand yet, but mid 90s Triumph Trident wheels look suspiciously similar to later model GS wheels, but in modern sizes and likely lighter. There'd probably be some modifications involved with the brakes though. It's something I'd like to try someday.
            Hi Burger, thanks for your post, I am using 1985 GSXR 750 Slabbie wheels front and rear, these are light weight wheels and have a bead to fit tubeless tyres safely. Ditching the inner tube saves 740 grams on the rear wheel alone. I was also keen to run 18" wheels front and rear as these offer stability, lower the centre of gravity, less effort in the twisties. There is a reason Suzuki used 18" wheels front and rear for so many years in the Endurance Races. Also, they are a similar design to the 1983 SD Suzuki wheels so they will look almost factory, almost. Front wheel needed some serious work to make it fit a set of 1982 OEM Kat forks, the stock Slabbie wheel is to wide and has to be turned down in a lathe and have the hub machined to mimic the Kat hub for speedo drive and brake rotors.

            For brakes up front going to try and adapt 2004 GSX750F calipers (lighter than OEM Kat) and for rear brake a 2005 GSXR1000 K5 underslung caliper. The rear brake is almost done and should be a winner.

            Will post updates tonight.

            Cheers,
            Glen.
            Last edited by Shin-Ken 1074; 09-25-2023, 03:54 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


              #66
              Originally posted by garyS-NJ View Post

              The mudguard inside brace is actually a fork brace and so you might want something up there.
              Hi Gary, yes, that OEM steel boat anchor of a fork brace is getting 86'd and replaced with a Daytona aluminium fork brace that weighs 330 grams including the 4 titanium bolts for the brace compared to the stock steel fork brace that weighs 800 grams not including the OEM 4 x steel bolts.

              Cheers,
              Glen.
              Last edited by Shin-Ken 1074; 09-25-2023, 02:15 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


                #67
                Hi Folks, the last week has been quite busy for me and resulted in almost no time spent working on the DW Project and no time at all on GSR. Some minor progress to report, the front and rear aluminium axle spacers and rear caliper torque brace are now away to be anodised, 10 days until they are back.

                I did manage to sort out the rear brake components and although not fitted with a line and fluid it has had a dry fit. Rear brake system compared to OEM:

                1982 SZ OEM steel rear brake pedal and bolt = 271 g.
                1982 SZ OEM steel rear brake torque brace & bolts = 438 g.
                1982 SZ OEM rear caliper, bracket and bolts = 1583 g.
                1982 SZ OEM rear master cyl and res, no fluid = 433 g.
                1982 SZ OEM rear brake rotor no bolts/lock tabs =2,170 g.

                4,895 g.

                DW 180 modified ally rear brake pedal and Ti bolt = 120 g.
                Aluminium torque brace made in the shed = 59 g.
                Modified 2005 GSXR1000 rear caliper and bracket = 1197 g.
                Modified 2005 GSXR1000 rear master cyl & res = 218 g.
                Aftermarket super light weight rear rotor no bolts = 550 g.

                = 2,144 g.


                DW 180 rear brake system comes in at 2,751 grams lighter than 1982 OEM Kat rear brake system, close to 57% lighter. That percentage will improve when the rotor bolts are weighed as the 5 DW180 rotor bolts are titanium compared to the 6 OEM steel bolts. When the axle spacers are back from being anodised and the rear end can be installed I'll give an accurate weight update. I don't want to make a mistake with the figures while there are parts being installed and removed to get them right so the tally will only be added to when parts are installed as a finished item.

                Cheers.
                Last edited by Shin-Ken 1074; 09-25-2023, 04:52 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


                  #68
                  DW 180 rear master cylinder mount bracket after removing 180 grams.

                  DW bare frame 3 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


                    #69
                    Sometimes Swiss Cheese works.

                    DW bare frame 2 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


                      #70
                      Centre stand mount brackets lightened.

                      DW bare frame 4 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


                        #71
                        Frame taken straight from being garnite blasted and primer applied 30 minutes later. This pic is after hanging the frame before the primer was applied. Used 16 mm round bar so the frame could be pivoted to allow better access for painting.

                        DW frame primed 1 by Max Mutarn, on Flickr
                        Last edited by Shin-Ken 1074; 09-27-2023, 12:11 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


                          #72
                          Frame pivot position, still bare metal, primer hasn't been applied yet.

                          DW frame primed 2 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


                            #73
                            Frame back from the Painter, very happy with his work!

                            DW frame painted 1 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


                              #74
                              Rear master mount bracket minus the rust and chipped looks much better.

                              DW frame painted 2 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


                                #75
                                Centre stand mounts looking fresh.

                                DW frame painted 3 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

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