Dan67's Hustler 950 Rebuild

[Dan67]

Kepp pushing Dan, looking good. I thought you were putting the at189's on it?

That was the plan until funds ran dry due to cost overruns. Gonna have to wait until just before the spring Busco ride.

[kpike52]

Have a good winter.

[Stonewall]

What did you decide to do about the chain hitting your skid plate bolts? Looking great, keep chugging along at it, and it'll be done before you know it!

[Dan67]

I made a bolt hole template out of cardboard. I cut 2 pieces 2" wide and pushed it down onto the bolts to make an impression of the bolts and I will to strap them to the strips of 3/8" HDPE with rubber bands tonight after I get kids to bed. I'll make a small hole with the cordless drill then go back with a larger bit. I'm hoping that they line up perfect and then I'll just spot weld them to the lower tub so they don't move out. The weather is supposed to be rainy but cool so I should get some work done the next few nights in the carport.

[lewis]

That was the plan until funds ran dry due to cost overruns. Gonna have to wait until just before the spring Busco ride.

That will really make the machine come to life. Keep plugging.

[Dan67]

Still slowly chugging away..

I'm still slowly knocking things out. I mounted 3 new grab handles to the top, tail lights, and the gas tank. Gas tank went on pretty easy. Used the old top and guess-a mated the center for the fuel cap and drilled it out. Placed tank on some blocks and then lowered the top back over it and blocked it up. I was kinda surprised just how accurate I was. I then placed the body band back over top it and started to mock up for the head lights, decided to mount them on the front bumper instead of on top the tub.



I do say that Hunter Green looks good on the body band and front bumper.. Think I will repaint the rear cargo rack the same color..

[Dan67]

Just a small update.. It's too dang cold to work outside in the carport this week. But I was off work last week and spent most of my time off sick, so not much got done. I was able to cut off the bolt lip from the old lower 950 tub. The lip will be my spacer to even out the gap from the front and rear frame supports for the bumpers and body band. The left side spacer is welded onto the 980 lower tub with all the old bolt holes filled. The right side is ready to be welded onto the 980 lower tub. The upper is finished awaiting to be bolted back together. I built my top tub with its own wire harness that plugs into the lower wire harness. The lights & fan are wired so they just plug up to the upper wire harness. Once I get the tubs together I will stop until the spring.

All that is left to do will be:

1) Install head lights and winch
2) Install the rear seat support w/ spacers for correct seat positioning (frame and tub spacers raised the upper body ~3/16")
3) Fabricate new grate for the rear
4) Fabricate tail pipe on the muffler for rear exhaust exit
5) Fabricate rear seat leg guard/floor pan
6) Fabricate support frame for engine bay fan
7) Install engine bay reflective heat shielding
8) Install T-20 drive chains and chain tension rollers
9) Fabricate rear bumper

I took off the week before the Spring Busco ride to finish up my build. If for some reason I am unable to get much done I can still ride it. All I'd need to do is just slap on 2 chains and their tensioners. I'll be solo so a missing seat/engine cover is not a deal breaker.

[lewis]

Keep Pushing!

[Dan67]

Just waiting on warmer weather and to finish a complete bearing and chain change on the Conquest..

[Dan67]

Just a small update.. Its close to being done.. Fired up the new 23hp Vanguard tonight for the first time.. Man, that sucker sounds good. Need to get a side exit muffler. The rear exit muffler is too low in the body and started melting my electrical tape on the wire loom in the back, I'll fix that later.. All I really need is cooler weather and some UN-interrupted time off from work.

[fmints]

Just a small update.. Its close to being done.. Fired up the new 23hp Vanguard tonight for the first time.. Man, that sucker sounds good. Need to get a side exit muffler. The rear exit muffler is too low in the body and started melting my electrical tape on the wire loom in the back, I'll fix that later.. All I really need is cooler weather and some UN-interrupted time off from work.

Glad to hear that you got everything going with the hustler! Can't wait to see some video.

[lewis]

Great show us the pictures!

[highrollinmopars]

Good deal any pics? Did you ever find some tires?

[russriders]

Hey Dan Ur hustler look good man ! If u want u can come my house and check out my side exit muffler see how I set up on my hustler .

[fmints]

Hey Dan Ur hustler look good man ! If u want u can come my house and check out my side exit muffler see how I set up on my hustler .

You can also look at mine and Jp's too. I think Racerone3 has a good setup also. He even used or made a heat duct like to channel the heat out.