Cylinder head gasket for GSF250v 1995

[kznbro2]

Hi All,
Well my bandit 250 is nearly ready now. The b....r fought the whole way ! The latest is the head gasket. I have been searching the web & local outlets for weeks now with no success. I did find a gasket in April but it is for the GJ74 and the GJ77A has a different size on the timing chain so it's a no-go . I heard I could reuse the gasket if I removed the black coating and redid it with 2K black. Easier said than done! The existing coating appears to be a thermoset resin (or similar) and conventional automotive paint strippers can't lift it.

The question: Does anyone know where I can buy a gasket SGP 11141-11D50?
 Rider to the question: Alternately; does anyone know how to get the black Suzuki coating off without damage to the metal gasket.

I looked into a laser cut replacement and the tooling cost was USD160 but then the material minimum thickness they could do was 1.5mm. The existing gasket is 0.2mm!

I really hope someone has some help as this is the last hurdle to getting the 1/4L Bandit burning gas again.
Cheers. .
Pete.

[kznbro2]

The Bandit started today with no water in, just to see if it ran. We put water in and ... No start!  Tore the head off again and found water in 2,3,4 cylinders. so I really do need a head gasket. We had painted the gasket with black 2K as recommended and were expecting a reasonable gas seal and no problems with the water seal. No Such Luck!.

I really find it hard to believe that nobody has had to change a head gasket on one of these bandits as this gasket fits all late 1995 through to 200 models!

Well tomorrow I go & buy some 0.8mm copper & cut a plain annealed copper gasket; as seen on early Austins, Morris's & MG's. Seems a let-down for a high performance engine!

Oh well! if it works ok; the bike doesn't mind.

  no gaskets anywhere mumble mumble moan. Even tried JDM

Cheers.
Pete.

[kznbro2]

Another update. The guys where the copper sheet came from put me in contact with a water jet company here. I went there and they are cutting the gasket now so I should have it this week end.  The owner of the water jet place showed me some other gaskets that they had cut for other vehicles. Beautiful! He also told me that they get a number of local race engine builders ordering copper gaskets because they perform better on high performance motors.  So; maybe soon to make noise & breeze down the road 

Cheers
Pete.

[kznbro2]

The story continues!  It turns out it wasn't the gasket leaking but one of the new barrels I had made that slipped down by 5 thou (#3 cylinder) which caused the barrel to fill with water when the radiator was filled.    The machine shop has the cylinder block now to re-face the top & while they are at it, the base too. They will tell me how much was taken off so that I can get a base gasket packing made up; if needed.

I hope it turns out to be worth it in pleasurable rides

Cheers.
Pete.