Hustler 945HK face lift

[KajunKrawler]

When i pulled the t20 out because of the loose mounting bolts i didnt stop there. I decided to tear it all apart to repaint the frame check all the bearings.
I have a few questions for the more experienced here:

Rusty frame:
Pics are of frame side rails in the front have some rust and scaling. This is the worst area. Appears that water sat in the machine for some time. Should i weld some new flat steel on the inside or just sandblast and paint?

Sprockets:
Appear to be in good shape to me. Best pics i could take with camera phone. Some oblonging of the axle/sprocket holes on the center axles i believe that causes some play. Is there a trick to correct this other than replacing? Where to buy new axle to sprocket bolt from?

Axles:
None appear bent. Outter bearings in real good shape. Going to leave them in place, just clean and regrease. Is it ok to put anti-seize on the axle where the sprocket bolts on and where the inner bearing rest? Going to put silicone between the outter bearing flanges as I saw on a post here somewhere.

Sure there will be more questions. Thanks!

[KajunKrawler]

Well I hope that the frame is ok because i just pressure washed it good and used Rust Restorer on it. The product works well from what i can see. Time will tell. Brushed on oil based rustoleum paint for metal. No one replied to my above post so i hope im not making things worse on myself. Please let me know if i am screwing up, i have a lot of time invested in this project so far. Would hate for a stupid mistake to cost me more time and money. I cut all the chain tensioners out and building some like brushcutter (thanks brushcutter). I cant find the size sprocket/axle bolts locally so will order them. I am going to weld the holes in the sprocket tubes and redrill the new ones. I still want to put anti-seize on the axles where the sprockets and bearings mount. I have read where this is ok and not ok. Going to used 3m caulk between the flange bearings instead of silicone. The bearings should be delivered today so stop me now!

[Mike]

I think you are in good shape. The frame doesn't appear to be too bad from your picture and the sprockets should be fine too. From what I can see in your pictures they are not too deformed. I would go ahead and put antiseize on the axles where the sprocket tubes slide over them. I don't see anything wrong with that. I have done the same thing on all of my machines. One time of having to remove a stuck sprocket tube from an axle is all it takes to make you apply liberal amounts of antiseize.

Good luck with the continuing build. Keep us updated of your progress.

[KajunKrawler]

Thanks mike, starting to put it all back together now, bearings are in. I picked up some o-rings, 7/8 x 3/4 x 1/16 for the plungers, look like they maybe smaller in diameter than what is on the plungers now. I got that size from a post on here somewhere. Can anyone confirm that size, it will be a couple more days until i put the t20 back together. Thanks

[racerone3]

i coated the inside of the sprocket tubes with antiseize on my racer and still had one so stuck only a year later, that i had to use excessive force to remove it. after that i built my wild wolf and used red grease (mobil 1 wheel bearing grease) on that machine. hopefully i'll get to do some riding again someday and bend a few more axles only time will tell if the red grease is better or worse than the antiseize. either way i think you would be making a mistake to assemble them dry. lube em up with something! it can't be worse than 2 dry assembled parts rusting themselves together.

[KajunKrawler]

I have to be honest that i WAS diappointed when i first got the hustler running. It was sluggish, chains popping all kinds of noises everywhere, but now im not. After the rebuild everything is so smooth. Im am definitly hooked. Just a few little bugs left and it will be perfect in my eyes.
It has the kohler k341 (16hp) single cylinder in it. It cuts out (motor stalling) when hauling butt across a semi-bumpie field. It all so cuts out when i do a fast u-turn. It has to be something going on with the fuel delivery i think. Maybe float in the carb? I think im just gonna pull it out and put the 16hp B&S ohv twin in the belly unless i can fix this quickly. New chain tensioners work very well so far. Had one bend but that was my fault because i didnt put a full weld on it.
Split shifters are killer. Thats all i am going to say about that. If you havent installed one yet, DO IT.
I am already planning on what to do with the 880 model that i have. The frame off the 880 is in very good shape. It is also made from steel twice as thick as my 945. My plan was to sell it because it was part of deal when i bought the 945 but now i want to rebuild it too. Hope my wife dont leave me! haha