Dan67's Hustler 950 Rebuild

[Dan67]

I wasn't able to get started when I wanted to today, but I did get some things squared out. I got 2 vacation days approved for next Wednesday and Thursday. Jury Duty next week was cancelled.. Started welding the 1/4" round HDPE to the sides of the bottom tub that was cut too small. I really did notice one thing with the USC model6 airless, works great if you do a small tack weld down the seem first before using the enclosed welding rods. I understand what some have said that after they welded just one side it would sometimes break, that is caused by "cold welds" when the pieces do not get a good fusion. Oh so I got about 3ft done tonight with about 16' more to go. I should get it done by Monday. Oh and I actually got Sunday off this week so that will allow me to get more done. If I can get the tub all fixed and the front frame fixed, I should just need to reassemble it all and wire it up. I might make Busco afterall. And we won't be going primitive, wife demands hotel stay.

[Dan67]

Quick update.. Took the frame to a local guy who is going to fix the front lip that supports the body band and winch mount. He is also going to fix a few another little issue on the frame. Bottom is repaired and I'm now filling in the holes on the top tub lip. I will drill new holes for body bolts soon. I should get the frame back tomorrow evening and then I'll start to reassemble the axles/bearings/sprockets. Should start to come back together rather quickly I hope.

[lewis]

Stay at it!

[Dan67]

Just another update. Just got back with the frame. He went ahead and got it done this evening and cheaper then his original quote. So tomorrow I can work on reassembly! I got some clips from work that I can weld to the inside of the tub to clip in the wiring and fuel line.

[Dan67]

I woke up this morning to a terrible migraine headache.. Wasn't until later this afternoon did it clear out. Thank you VA for the pills, they work wonders. When I got going I realized I forgot to paint the frame. Its painted now and dried enough to start putting stuff back on it. I still have not received my inner bearing flanges so I called the guys at Buffalo Bearings. Apparently someone forgot to fill my order and ship it, they said they will ship it today, overnight for free. Got some things I can do in the meantime. I hope I can get some weekend time off and hopefully I'll make it down for Busco.

[Dan67]

I just finished putting some stuff back on. Laterals are now on a single all-thread rod. Cut the lateral rods down to match. Added grease fittings to the laterals on the all-thread. Put the FNR selector back on and the control rod for it. New solenoid and reused the wire that goes back to the motor starter. New all-thread to hold the battery down, I mangled the old taking them off. Oh and a fresh spray bomb paint job on the frame too today. Think I'll add the new winch remote and throttle to the laterals tonight while I got some time after kids go to bed.



Went back and added the Max throttle, winch remote, and new hand grips after I got the kids to bed. I'm dog tired now, but I do feel better that I was able to get some things accomplished while I wait on the inner bearing flanges.

[Dan67]

Ah crap.. I tired to redo my laterals to use a 3/8" rod through bottom instead of the 5/16" rod I originally used. The 5/16" was to flimsy and I wanted them more rigid. I broke them now I need to get them rebuilt. Til then I am stuck. I seriously doubt that I can make Busco now. Too far behind now and no time to catch up. I'll keep plugging away on it and hope to have it ready before the spring run.

[Noel Woods]

I don't know how but I've missed this thread until now. Nice job DAN67, this machine is coming along well. Its certainly got all the right stuff. What are you doing for chain adjusters? The 23 HP Briggs will give you plenty of go. Got the same engine my Argo Frontier, and its got everything you'll need and then some. Keep the progress digitals coming. I really enjoyed the show.

[Dan67]

For the chain adjusters, I have to thank Raceone3 and Don. Raceone3 did the original design, I just reused old parts that where still good. And Don did the design for the 2 rear adjusters get tension on the chain. I just combined the best from both.



I went back and redid the laterals. I installed the new winch remote control box. I feel much better now and I hope to get the frame back in the body soon. I hope to get the T-20 back in and start running the wiring and fuel line.

[Dan67]

Well today turned out to be a disaster! I had just gotten the skid plate on and I was in the process of turning it over to begin installing the frame. And the rivets started pulling loose from the inside. The rivets are a complete failure. I now have 200+ holes in my lower tub. I am so freaking mad, I used blind sealing rivets from McMaster-Carr, I made sure they where long enough and they are. But when you start to ratcheting down rivets they expand in the middle and not at the end to make a plug. I might have to jst break down and use 200+ 3/16" bolts and nuts and pack them with silicone to seal them.



I went by Lowe's, and I will decided to just scrap the rivets and go with #10-24 machine screws with bonded neoprene washers. I'm sure I can make it work. I just really mad about wasting good money on rivets that won't expand as they should. I am going to return the rivets to McMaster-Carr. on Monday. Every step I go forward ends up taking two or three back.. I am really having a hard time staying focused on this build. Starting to feel like I am about to the point I send it all to the land fill, but I have way too much money tied up into this POS.

[jerseybigfoot]

When using blind rivets you use a back up washers made for rivets on th eblind side. I would stay with the rivets.

[highrollinmopars]

Hey did you ever get the body lip fixed where it was trimmed to short? Just wondering how that worked out for you. Let me know before you haul anything to the landfill I know your joking but I would take it off your hands before that happened.

[Dan67]

I got the lip fixed awhile ago, welded back a 1/4 rod the entire length of the lower lip. I've been fighting the skid plate the last few days. I hope to get it licked today and stick the frame back in later today. Hopefully then progress will be much smoother.

[highrollinmopars]

Good luck with it.

[Dan67]

I finished the skid plate the other week, took some time away from it to get a breather and time to think about whats next. Its coming along slowly now and soon I will have to stop for the winter. There is no heat in the car port. Just a few minor bugs to work out now. The T-20 mount needs to be trimmed back a bit. I'm using threaded studs on the t-20 bottom and they are a bit thicker then the original bolts. I have the inner bearings installed but not tightened down. Once I get the T-20 mount modified I'll firmly installed I'll stick the frame back in for good and get the axles, sprocket tubes, etc in. I'm trying to get as much down on the frame before I reinstall it. Really trying to avoid spending time with my head in the tub and my butt in the air.