1984 Katana 7/11

[pete]

Cheers Scott!

I'm enjoying finally getting some progress going again and can't wait to get that shed ready to paint, calipers and master cylinders will be the first things done ready to rebuild once the various bits arrive for them.

[pete]

A little disappointed this morning... was watching a genuine GSX1100 manual and the Kat supplement on eBay, no bids sitting at 99 cents so I waited up all night to get them cheap... seller ended them early so I missed out... I knew I should've put an early small bid in! Oh well...

While I haven't touched the Kat as such, I've been concentrating on finishing the shed ready to paint stuff like the calipers.

The end where the shelves are needs to be protected, so I put a bit of a frame work up and screwed in some press stud bases.



The best colour tarp I could think of was silver (never seen a white one), so I started putting the press studs on it so it will seal that end up as well as possible. Not finished obviously!



I've also had a re-think on the fan/filter idea. Given I'll only be doing occasional paint things in there, I think my big plans are just way too much and overcomplicated, so I'm going to do something a lot more simple.

I'm thinking I'll build what will basically be a recirculation box on top of the compressor cabinet, and in there will have a fan and some paint booth filtering material. It'll exhaust back into the shed but I'll do that through an activated carbon filter (like in a range hood).

I'll also put an inlet filter of sorts into the temporary wall piece I made for the extension so some fresh air can get in rather than just recirculating the same air.

I know my original plan of positive pressure and inlet and outlet will give the absolute best environment to paint in, but it's way too much overkill and is going to keep taking way too much time from the Kat. It'll also be a waste once the Kat is done.

Also, with this method, I don't have to be so paranoid about making sure the shed is 100% sealed unlike a positive pressure environment. It still has to seal well to keep the fumes in and I'll have to make sure I get it pretty clean before painting, but at least they won't be forced out.

[pete]

I've forgotten to mention I spoke with the seat guy last week and he had an operation so more delays with the seat unfortunately. He's back on light duties already so hopefully won't be too much longer before he's back in action fully. I'm not going to hassle him while he's still recovering though.

I got a present in the mail yesterday... caliper and master cylinder stuff! Ordered these before Christmas but the rear piston and seal set was back ordered so they were a bit delayed.



The box has the rear piston and seal set which was the big gamble... does the kit from the 84 GS1100G work for the Kat caliper?



Sure does!! I already knew the seals and boots were the same part number so surely the piston was the same, and yep it is. I didn't note the measurements but I used the verniers to measure the height, outside diamter, inside diameter, groove height, etc. and they are all the same. Nice to have a win!



Next step is to prep the calipers, brackets, and master cylinders for paint.

The shed's getting closer... put an exhaust fan in as an inlet fan in one of the doors to get fresh air in. I put some fly screen on the outside to stop the bugs getting sucked in and got some cheap universal air con filter material for the inside to stop the dirt and dust getting sucked in.





I thought I had my recirculation box pretty close but a pedestal fan motor just won't drive a belt driven fan, so I found an alternative on eBay dirt cheap instead so I'm just waiting for that to arrive.

[Big Rich]

That's good news on the brake parts Pete. And that fan in the shed will make a huge difference!

[thebrandonbeezy]

Man, i love this build

[thebrandonbeezy]

Where did you order the caliper rebuild kit?

[pete]

Cheers guys! Yep Rich, while the fan doesn't move a huge amount of air it will definitely keep some fresh stuff coming in, and hopefully combined with the recirculation box filtering out the overspray and fumes it should be a much better environment than I had in the garage when I did the 450.

Brandon, I get my genuine parts from a dealer down in Melbourne over here called Mick Hone. They are *the* best to deal with in Australia for genuine Suzuki parts and in particular Kat parts as Mick Hone himself used to race.

I also received this in the mail yesterday, exciting!

Paid a little more than I wanted but after missing out on the cheap ones on eBay the other week I didn't want to miss the opportunity again.



And it includes the Kat section!

[thebrandonbeezy]

You cant beat the service manuals. Im a tech at my local chev dealer and all of our manuals have been transferred to online but watered down, i like to go up stairs from time to time and grab one of the old paper manuals when im working on an older vehicle

[pete]

Yep, there's nothing quite the same as being able to flick through those pages. I have my old work laptop here and a soft copy, but it's just not the same. I have a re-print for the 450 I bought on eBay and it's now well used.

[nvr2old]

Bump.. I just couldn't watch your project move off the first page, Pete..caught it just in time..now get back to work..

[pete]

Haha cheers Larry! Unfortunately I haven't had a lot of time lately. It's been way too hot to think of doing anything at night as well. I at least got a motor sorted to run the fan for the recirculation box, just need to finish mounting that up and get the box sealed. Then I can get back to prep'ing the calipers and master cylinders for paint. Sounds quick and easy but probably not... they're predicting 38 celcius (100.4F) for Sunday which is the next chance I'll get, so not sure how much I'll get done.

[nvr2old]

Holy crap..100 degrees! We have 3 feet of snow right now. I can understand why it would be difficult to get anything done in that kind of heat. I always look foreword to your progress, though, Pete. I'll be patient.

[pete]

The humidity has been the biggest issue, stays warm at night and you're sweating sitting still...

Anyway, hopefully I can get at least something done tomorrow. I'm looking forward to getting back to the point where I can do at least one little thing each night like I did on the 450. That helped get some good progress done.

[pete]

Well no Kat progress done but I completely surprised myself by getting a bunch of stuff done on the recirculation box yesterday.

I got the filter cages sorted, motor mounted up, another of the internal walls done, and the motor room door on.

All that's left now is the left internal wall where the belt channel goes through, some bits at the top of the front, and some sealant then she's ready to roll as soon as the filter material arrives.

It's not the prettiest but I'm just using whatever offcuts I have left around the place.

[thebrandonbeezy]

Well no Kat progress done but I completely surprised myself by getting a bunch of stuff done on the recirculation box yesterday.

I got the filter cages sorted, motor mounted up, another of the internal walls done, and the motor room door on.

All that's left now is the left internal wall where the belt channel goes through, some bits at the top of the front, and some sealant then she's ready to roll as soon as the filter material arrives.

It's not the prettiest but I'm just using whatever offcuts I have left around the place.

This is a serious case of "when life gives you limons, make lemonade" love it man