1984 Katana 7/11

[pete]

I finally got back to finishing the initial sanding of the cowl, and rubbing my fingers all over it tells me no more lumps and bumps so it's definitely time for some high build primer.

Untitled by starpoint73, on Flickr

Untitled by starpoint73, on Flickr

Untitled by starpoint73, on Flickr

Untitled by starpoint73, on Flickrlickr

Now to finish sanding the front mudguard then move on to the tail piece and side covers.

I also need to finish dismantling the gearbox to finalise the parts list I need to order, and that should be happening within the next couple of weeks.

[thebrandonbeezy]

You mentioned your 450 on the other thread, been kinda interested in it after seeing the quality of your work on the kat. Only problem is your build thread is full of photobucket... i gather you know where im going with this lol..

[pete]

Ah, yeah... good ol' photophucket... I deleted my albums after their ransom demand so none of the photos are online at the present time.

Right now she's no beauty queen, she's a daily rider and looks it, and after the morning of New Year's eve she's a little worse for wear after encountering a bit of oil on the road. I'll see if I can get motivated to post some older pic's up in the old thread again.

[pete]

I haven't made much in the way of progress lately although I pulled the Kat out of the shed on Sunday in order to commit a tidiness and I figured that was a good time to make sure the front cowl still fit properly.

Still fits like it should:

Untitled by starpoint73, on Flickr

I also got the gearbox dismantled last night and I was happy to see there was nothing else unexpected, so I'll stick with the plan of replacing 5th drive/driven gears, replacing the bearings/circlips/washers/etc. and getting 2nd welded on.

Untitled by starpoint73, on Flickr

Roll on Thursday when I should be able to place the big order...

[nvr2old]

The fairing looks to've turned out real nice, Pete. Go ahead and squirt a bit of primer on it..you know you want to.....just to see it all in one color..c'mon...do it, do it..

[pete]

Cheers Larry, so far so good! And yes I most definitely want to

I gotta buy it first though

I'm taking next Monday off to visit the paint store that sells PPG paints locally. I suspect they'll have to order the 13L in for me but I'm hoping I can at least pick up the primer while I'm there so I can get that done in the next few weeks.

[pete]

I gave the crankcases a run over with paint stripper on Sunday and found a little gem at the back of the stator area. Initially I thought broken drive chain but I don't think that could be it.

I'll need to give it a bit of a clean up and smooth it out before I paint, gotta mke sure it remains oil tight.

Untitled by starpoint73, on Flickr

Untitled by starpoint73, on Flickr

Then on my day off yesterday I went up to the paint shop and got all my paint needs.

Untitled by starpoint73, on Flickr

No excuses now, I need to pull my finger out and finish preparing the bodywork so I can get the shed cleaned up ready to paint.

[dorkburger]

Those finds suck. A few years into owning my ES I found that the entire front engine mounting lug had been broken off and welded back on. In other words, I feel your pain...

[Rust_to_Redemption]

Looks like its been repaired with JB Weld? Never used that on aluminum, but I did once repair a go cart valve cover with that stuff. Pretty sure the JB Weld is 20x stronger than the aluminum, but I would check to make sure that it is formulated for use with it. Looks like a little piece has already chipped off, which would worry me a little bit.

[dorkburger]

I think that when Larry ( NVR2OLD ) did his Honda 400 he repaired a broken off cooling fin with JB Weld... as in made and formed a new one.

[nvr2old]

Yes, I did. The entire front portion of that fin was broken off. And it worked beautifully. JB Weld is a really amazing product. The surfaces all have to be surgically clean, though.

IMGP3964 by [url=https://www.flickr.com/photos/156482494@N02/]

IMGP3970 by [url=https://www.flickr.com/photos/156482494@N02/]

[Rust_to_Redemption]

JB Weld is a really amazing product. The surfaces all have to be surgically clean, though.

Not sure I would trust the worksmanship of a PO. As you said, JB Weld Works best when the surfaces are very very clean. Seeing a piece already chipped off makes me question how well the PO may have "repaired" the fault.

[pete]

Yep it certainly looks like JB Weld to me, that's the first thing I thought of when I saw it, and yep where that bit chipped off does tend to tell me it wasn't done all that well.

My plan is to file/grind/sand/whatever it back as much as I can to see how well it's stuck on there, give it all a really really good and thorough clean (despite the cases being pressure washed twice so far) and then apply fresh JB Weld over it.

I'd be reasonably confident it was oil tight once that's done, just gotta take good care to make sure the gasket surface stays level with the rest and make sure there are no file marks or whatever in that surface.

Larry, that repair is spot on too!

Cheers guys!

[pete]

What's in the box?

Untitled by starpoint73, on Flickr

Yeah baby! Now we're talkin'!

Untitled by starpoint73, on Flickr

This should also be everything I need to get the bottom end sorted except one wave washer on back order and the sump cover gasket which I completely forgot.

Untitled by starpoint73, on Flickr

I did lash out a bit and grabbed a new headlight frame as I did a good job distorting the one I had to fix up when I welded it, and I also now have a grab rail there as it's a bit awkward putting it up on the centre stand without somewhere to steady it.

Obviously the Kat fund is a bit anemic now... and it's time to take stock of where I'm at and work out everything I need to do to get her finished.

[Charlie G]

Wow Pete, it's always a good day when the parts arrive!