1984 Katana 7/11

[tatu]

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.

You should try using a pointed stick.

[pete]

You should try using a pointed stick.

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.

[ShadowFocus603]

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.

[pete]

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

[nvr2old]

Bump. Hey, Pete..haven't seen an update for a month. Everything OK with you..?

[pete]

Hey Larry, yeah all good here but no progress unfortunately. Still waiting for the seat to get done (upholsterer has been crook) and got delayed getting the 450 seat ready for him. Just finishing two weeks' leave from work but had to enclose the back deck, so nothing done at all unfortunately.

I'm still hoping to get the seat back in time to get the frame etc. powder coated before Christmas but time is fast running out.

[pete]

Still no sign of a seat, so I figured I'd move on and get the shed ready to paint in and start on the calipers. At least I can make some progress that way.

So, first step with the shed is to finish up the little temporary expansion bit so I've got some room to move around while spraying. Bit hard to get a photo of as there's not a lot of room, but when the doors open out there's a little section of wall that will slot in between the two doors, and a little section of roof that will go on top of that area.

The little wall section is just a frame at the moment, need to get some cladding for it.





I've yet to work out how to attach the roof when it's up there and it needs to go on a bit of a slant, but you should get the idea at least.

It's also hard to show but the extra room this provides is impressive!



Then last night I put a loaned caliper piston tool to use and got the calipers mostly dismantled. Even with that I couldn't do more than rotate the front pistons, so I'll have to try the compressed air next weekend. The rears came out easily.

Definitely need a paint job and a rebuild! Hopefully I can order the bits this week.

[ShadowFocus603]

I did compressed air trick when I rebuilt the calipers on her 750L. Just be careful. A little air goes a long way. I used too much and damn near hurt myself when the first piston shot out and did a 7 point ricochet in the garage.

[Big Rich]

Yep - plenty of potential for disaster when you use air. You have a good head on your shoulders though Pete.

I recently had to rebuild one of my 6 pot Bandit calipers. Trying to get a single piston out at a time can be near impossible, so I cut up a thin piece of wood. One side had a notch cut on the outside (so only the outer pistons could come out), and the other side had a notch cut from the center (for the middle pistons to slide out).

[Fjbj40]

Put the caliper in a sturdy cardboard box. When the piston pops it stays in the box as does any residual fluid.

[pete]

Cheers guys, I had to do the compressed air trick on the 450's caliper and I stopped the flying piston by stuffing a rag in front of it, worked well!

I got a hot tip to persevere a bit more with the front caliper pistons though but still no joy on those yet. Sprayed a heap of Inox around the seal and in from where the banjo bolt goes and used a block of wood to push the pistons back in to try to break any grip left on them. I'll keep persevering with them during the week but if there's no success by the weekend I'll break out the compressor.

I took the front master cylinder off the Kat last night and tore it down as well. Not in bad shape but looking at the state of the rubber bits and the little bits of corrosion starting here and there I'm definitely glad I'm rebuilding it also. It also lets me paint the mirror mount bit black along with the rest.

At least now I know the piston and cup set I got a while back is the right one too.



I also ordered the front piston sets and caliper axle boots, a rear master cylinder piston and cup set, and the 84 GS1100G rear piston set from our friends at Mick Hone yesterday (matching part numbers for the Kat seals). The rear set isn't in stock but once it arrives we'll get to see if the gamble pays off with it being the same as the Kat set.

In case you're not aware the rear caliper piston set is NLA from Suzuki but the seals and boots on the 84 1100G (and a few other models) are the same part number, so given how Suzuki likes to share bits between models I'm taking a gamble that the pistons are the same as well.

[IanC]

Cheers guys, I had to do the compressed air trick on the 450's caliper and I stopped the flying piston by stuffing a rag in front of it, worked well!

I forgot to put a bit of wood in front of the piston once and stopped it with my sandal-clad big toe. That was pleasant.

[pete]

I bet that tickled!

I always wear my extra tough safety thongs so I should be fine...

[pete]

Firstly, Merry Christmas you lot!!! Hope you have a good and safe day and get lots of cool stuff under the tree! Kat stuff preferred of course

This has been distracting me a bit... between last Sunday and yesterday morning I now have the temporary roof and wall bits done, just need another coat of paint and some latches or whatever to hold them in place when they're in use. Still can't easily show the extra space it gives.

Still need to work out how I'm going to seal it while spraying but that should be the easy bit.





I finally got a chance yesterday to give a borrowed master cylinder a shot, and yep, both pistons out nice and easy.



They're both actually in pretty good condition, but I still wouldn't take the chance if I knew it and would rebuild them anyway. Plus, this way they can get a shiny new paint job.

[gs scott]

Merry Christmas Pete!
Awesome project!! I'm sure enjoying watching another Kat come to life. Keep up the great work!!