New hustler project - bucket of bolts

[dirtdobber]

Dan you are exactly right. I have already found three small cracks and there are probably more. I do plan to beef up the T20 mount.

[dirtdobber]

I haven't done a very good job keeping this post current with my progress, which has been slow by the way. Nontheless, here's a few pics.

Fashioned a new engine mount. I gave it a little adjustment with a couple of push bolts. It's just a piece of 1/8 inch angle on top of 1/4 inch angle with slotted holes.
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I've slowly been building new tensioners. I'm using angle iron to make telescopic tubing...much more sturdy than the original Hustler tensioners.
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If I can ever get through with frame mods it will be off to sandblasting and paint.

I fired the engine up the other night and other than a bad spark plug she purred like a kitten.

[dirtdobber]

20160626_182544.jpg20160626_182536.jpg20160625_101415.jpgFinally got everything sandblasted and primed.

[dirtdobber]

I haven't done a good job of keeping photos posted, so I'll try to catch up.

got a good coat of glossy black paint on everything and got the t20 mounted, steering sticks mounted and linkage installed. Same for shifter, and fabed a battery box.20160705_054544.jpg20160705_054608.jpg

My helper is 20 years old is more interested in girls (which I understand!) so I had to build me some help! 20160707_055327[1].jpg

It's been a slow process as I have had to take care of a variety of things along the way, such as repairing the bolt holes in two sprockets and one axle, and fabing new shift linkage that attaches to the diamond shifter on the T20. The pieces that bolt into the T20 and recieve the linkage were just sloppy, so I took some 5/8 hot roll, cross drilled it for the 5/16 linkage, and then chucked it up in my drill press to turn it down to 5/16 to pin to the diamond shifter. Spun it in the drill press and uses a hand grinder to get it close to size then finished it with a file. It worked out very well.

I'm in the process of getting putting the axles back in. Got 12 new bearings from Bufffalo Bearing (very helpful folks and great prices). I'm going to cut some type spacer to put between the sprocket and outer bearing, which will keep the axle from sliding out (just a little reinforcement for the set screws and locking collar on the bearings). The shoulder on axle at the inner bearing will keep it from sliding in.

I've got to make a decision on tires and wheels. That has actually been the hardest part of this process. Swim vs. mud vs. price, vs. 8" or 9" vs. what tire diameter will fit, etc.

[ARGOJIM]

Nice work, the next picture is a major milestone.

[SeanD]

It's so nice and bright in your garage.

So with the tensioners- what happens to the original tensioners that is bad? I just have zero experience with thrashing on a Hustler. Do they just twist and go out of adjustment or what? I need to fix whatever the problem is now, not after paint!

[dirtdobber]

I don't have any experience with them, as this is a first for me. The originals look weak in that they rely on that little threaded plate to hold them in place. My C channels were bent so I could tell they had problems in the past.

[dirtdobber]

20160718_205122[1].jpg20160718_211332[1].jpgSlowly but surely making progress. Got the frame and axles in along with 5 of the 6 chains. Set the engine in last night and breathed a sigh of relief when it fit. I was afraid it would hit the back of the tub but I have about an inch of clearance. Still haven't made a decision on tires/wheels. Have to get key switch, amp gauge, build wiring harness, get choke and throttle cables....all I lack is finishing!

[Andyman]

Looking sharp

[dirtdobber]

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Still slowly making progress, but here's what I've done since the last post:
Fabbed up a front bumper
Built wiring harness (new key switch, amp gauge, all wires and connections, rectifier)
Got headlight covers polished up and reinstalled
Rims sandblasted and painted
Got some Rawhide III's to go on it
In the process of fabbing the floor pans and exhaust system. I'm going to add a partial body band that will wrap around the front. I'm adding a winch and I will feel better if it is anchored to the bumper and body band, since it all plastic.

[dirtdobber]

Got the rawhides mounted (it took 30+ psi to seat them) and made me a tire caliper to get each tire's diameter just right.
Tire Caliper.jpg
Getting pretty close to riding.
Close to finished.jpg

I had some carpet left over from a pontoon boat project..... I may be the only goober with carpeted floorpans in a machine that lives in the mud.

[dirtdobber]

Finally finished!!!! Its been a slow process but this thing will boogie!! Here's some shots of the finished product.
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Had a little debacle with the fuel tank, but thanks to ArgoJim it's all good.

To recap, this machine has:

New transmission bearings, seals and thrust washers
New drive clutch and belt
New engine mounting plate and vibration isolators
12 new wheel bearings
New Rawhide III's
New wiring harness, new key switch, new amp gauge, new solenoid, new battery
New fuel line, shutoff valve, filter
New bumper and partial body band
New winch
33 feet of new chain
6 new chain tension idlers
New throttle and choke cables
New floorboards with luxurious carpet
New padded front seat bottom and back
Powered by a twin opposed cylinder 20 horse Briggs.

Now, when I get my 4 wheeler fixed, me and my boy are going down the road to the Sardis Lake recreational area for a ride!! I'm sure I'll have some fine tuning to do after a good ride.

[Noel Woods]

Sardis Lake, now your talking my language for some crappie fishing / feast, as well as a ride in a nicely restored Hustler.

[ARGOJIM]

She turned out nice, after a ride or 2 you could rejuvenate the upper body with a heat gun to loose the chalky fade. I'd take it easy on any ditches until you find the angle that exhaust may hit. Great job on the seat.

[Mike]

Nice work! You should have a machine now that will give you lots of trouble free riding. Have fun with it.