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Classic Bike Trackdays

A Katana................in here................?????
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gagster55
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Joined: 04 Dec 2006
Posts: 219
Location: West Yorkshire

PostPosted: Fri Nov 13, 2015 11:24 pm    Post subject: Reply with quote

when I was looking for a Sprint ST speedo, it turned out cheaper to buy a whole instrument console - only £40 plus postage off everyone's favourite auction site..........




included in the comprehensive display of instrumentation is this dinky electronic time piece.....



which I wanted to incorporate into the project - but where could I fit it without it looking like a cheap add-on..............?

here of course - into one of the accessory ports thoughtfully provided by Suzuki.......



a bit of measuring and drilling of 2 holes to accomodate the hour and minute adjustment buttons and......



it's in the r/h panel so at least I will be able to see it when the bike is at rest on it's sidestand Very Happy
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jim157



Joined: 04 Jul 2010
Posts: 77
Location: Norwich

PostPosted: Sat Nov 14, 2015 9:10 am    Post subject: Reply with quote

What a brilliant project, great stuff!
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gagster55
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Joined: 04 Dec 2006
Posts: 219
Location: West Yorkshire

PostPosted: Sat Nov 14, 2015 6:14 pm    Post subject: Reply with quote

frame bending time..........

checking the headstock for accuracy (triangulation of readings taken around swingarm pivot point, upper headstock and lower headstock) using this trick robotic arm thingy, being held by a non-robotic arm........



and comparing the results with the factory data for a GSX1100S frame (same frame as 750)........



that looks close enough - so time to bolt it into the jig and centralise it.........



and take some measurements of the rear subframe (which I knew was twisted)........



which gave us this set of readings........



time to get tough - installing the bracing pieces and the hydraulic jack......



ooh - the tension - the pressure.......



another bout of measuring, some final tweaking and the frame was pronounced straight. Now I can get on with taking the measurements for the rear shock mounts. Very Happy
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gagster55
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Joined: 04 Dec 2006
Posts: 219
Location: West Yorkshire

PostPosted: Sun Nov 15, 2015 12:18 am    Post subject: Reply with quote

jim157 wrote:
What a brilliant project, great stuff!


cheers Jim - glad you're liking it.......
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gagster55
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Joined: 04 Dec 2006
Posts: 219
Location: West Yorkshire

PostPosted: Sun Nov 15, 2015 5:50 pm    Post subject: Reply with quote

so - knowing that the frame is now straight, today I set about locating the lower shock mounts onto the 3MA swingarm. The Gazi shocks that I purchased are 300mm between eye centres, adjustable to 310mm max. My ideal measurement is 330mm + adjustment, so the lower shock mounts would have to be moved nearer to the swingarm spindle.

First, I drilled a piece of flat bar with a 10mm hole (lower shock mounting bolt size) and a 12mm hole (top mounting stud size) at 330mm centres, then attached it to the top mounting and jacked-up the swingarm until the lower bracket sat flush on the arm, like so..........



I then sized and fitted the correct bushes for the shock mountings - Gazi shock sets include 4 of each of 3 different-sized bushings - 10mm, 12mm and 13mm.



with the swingarm still positioned at the 330mm height, I fitted the lower mountings to the shocks and attached them to the frame, thus.............



ensuring both lower mountings were sat flush on the swingarm, I took the measurement, both sides, from the trailing adge of the mounting to the end of the swingarm box section - exactly 141mm both sides - result Very Happy

The swingarm can now go and have the lower mountings welded on, and I'll set about making a new inner bushing for the pivot end to take the smaller diameter Katana spindle.
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gagster55
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Joined: 04 Dec 2006
Posts: 219
Location: West Yorkshire

PostPosted: Thu Dec 03, 2015 8:06 pm    Post subject: Reply with quote

they're on...............

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gagster55
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Location: West Yorkshire

PostPosted: Tue Dec 08, 2015 6:41 am    Post subject: Reply with quote

more treasure from Japan Very Happy

full lockset - 1 key fits all - spare key included, £23.......



sidestand, spring and bolt for £8........



screen mounting brackets, complete with screws and rubber bushings cost me £7 - the silver screen 0.50p......



reg / rec unit (for show only) £3.50............



full GSX750S1 airbox unit - a bargain £1-50............

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gagster55
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Location: West Yorkshire

PostPosted: Tue Dec 08, 2015 6:42 am    Post subject: Reply with quote

the rear, air filter section of the airbox after being attacked by a rampant hacksaw.......



and the bit I need, fitted in place, but yet to be cleaned-up - this will disguise the 2T oil tank on the r/h side of the bike.......





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gagster55
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Joined: 04 Dec 2006
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PostPosted: Tue Dec 08, 2015 6:44 am    Post subject: Reply with quote

look away if you are squeamish, or Steve Lucky 7..................... Wink



its not that Steve's quality parts don't fit, just that they don't fit in my case as I want to retain the air filter box. So I have to fit Steve's tray upside-down, like so.....



the holes in the rear of the tray allow access to the bolts that secure the airbox to the frame. As the tray is being fitted upside-down. I also had to drill a hole in each side of the tray to enable it to be secured to the frame with tie-wraps.......



and with the air filter box in place.......



next - I have to cut a hole for the 2T oil filler neck to peek out of...........
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gagster55
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Joined: 04 Dec 2006
Posts: 219
Location: West Yorkshire

PostPosted: Fri Dec 11, 2015 1:15 am    Post subject: Reply with quote

back to the clocks - how to make a simple facia for this........



you need Blue Tac.........



a suitable material for the facia (I used some Plasticard)......



a pen............



and a bandsaw helps too........





re-attach template...........



to facilitate final shaping........



out with the compass cutter.........



just needs spraying and a couple of Katana decals and its done........

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Bitacticus



Joined: 13 Apr 2009
Posts: 276
Location: Netherlands

PostPosted: Fri Dec 11, 2015 5:27 am    Post subject: Reply with quote

Outstanding job

looks fantastic

keeping the eye on the detail is what realy makes a project stand out

Regards Erik
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The Cameraman



Joined: 22 Aug 2015
Posts: 608
Location: Lancashire

PostPosted: Fri Dec 11, 2015 6:17 am    Post subject: Reply with quote

Hi Gagster,

fabulous work, keep it coming.

Regards

Reggie
_________________
Kindest regards


Reggie
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gagster55
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PostPosted: Sun Dec 13, 2015 6:27 pm    Post subject: Reply with quote

Thanks for the kind words guys ! Very Happy
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gagster55
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Joined: 04 Dec 2006
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Location: West Yorkshire

PostPosted: Sun Dec 13, 2015 6:28 pm    Post subject: Reply with quote

this............



is the 750 Katana airbox inlet trumpet that came with the airbox I bought from Japan, and it just so happens to fit this......



very tightly. And is also an interference fit in here......



so - when its attached to the 2T oil tank neck and fed upwards through the hole in the undertray.....



it becomes an oil-dribble protector........

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steezin_and_wheezin



Joined: 07 Jul 2015
Posts: 68
Location: Radford, VA(USA)

PostPosted: Mon Dec 14, 2015 3:24 pm    Post subject: Reply with quote

Incredible build!! Looking forward to following along
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