Hustler Restoration Question

[Fatdog]

Ok guys I started taking the Hustler 950 apart today...My question is How did you guys take all the screws out to split the top and the tub apart.These screws are rusted out and rotten. I can't drill them out because it generate heat and starts to melt. Any Ideas please help...

[mudbug3]

I used a dremil tool to grind off the nuts on the bottom of the screws that hold the two tub halves together.

[Stonewall]

I clamped visegrips on the screwheads and took them off with an air impact.

[Fatdog]

These screws are flush head phillip. I can't grab them with anything...

[amphibious drew]

Never done a hustler, but if its Not ABS, put some acetone on each screw and nut. If it IS ABS, use some deep creep or other wd40 type stuff. Then go get an impact screw driver. They are typically black, thick, and can accept different types of bits. You use a 5lb sludge hammer to hit the bottom of the screw driver. A mechanism turns the driver with the downword force to free you screw. Let the chemicals work overnight and then use your impact screwdriver the next day. To apply the acetone i use glass eye droppers. Be very carfull not to suck it full or lay it flat as the acetone will disolve your rubber bit on the end. Good luck.

[Stonewall]

These screws are flush head phillip. I can't grab them with anything...

You have to hold your mouth just right... If you try hard enough, you CAN get some vicegrips on the heads.

I don't believe Hustlers were ever ABS, only fiberglass and then HDPE. Your 950 would be the latter.

I'm not sure how well an impact driver like Drew suggested would work for you though. It will be hard to support the body, hold the bottom nut, hold the driver and sledge it all at the same time...

[bstewart63]

I used a high quality very sharp drill bit. Drill fast and you might need to have someone hold the nut on the bottom to keep it from spinning. We didn’t have any trouble with melting. You can spray with WD to help it cut and keep it cool.

[kpike52]

I started to take mine apart last week (Hustler950/Sidewinder). The lip was attached with 1/4-20 oval head Philips. 3 broke in half from the torque driver. I changed over to a manual ratchet. I removed most that way, but still twisted a few heads off. The ones that would not break loose, as happened to you, I used a hand grinder with a thin (.040) cut off blade. Plunge from the top, not from the side. It was very easy to remove the heads without causing excessive heat.

[Fatdog]

I went to Home Depot a bought VERY SHARP 5/8 drill bit for metal. I put a wrench on the nut and drilled the phillips head out. I used WD-40 to cool the bit. I had all them off in less than an hour.

[Fatdog]

Restoration Update!

After removing the top finally...I dug in on everything else.
1. Removed the old chains.
2. Removed the 16hp Kohler, tranny still in.
3. removed the tires. These where 21x11x8's...I'm guessing these where the originals.
I'm going back with 25x12x?? I'm not sure what size rims to buy yet.
4. I removed 5 of the 6 axles.
The stuck axle is the middle left side. The axle is stuck in the center bearing and want budge! I took a long punch inserted it from the opposite side and a BIG hammer and beat the heck out of it...still no budging. Has anybody got any suggestions on how to remove this stuck axle?

[racerone3]

hit the axle with a sledge a few times (trying to shove it back into the machine). Then take a grinder and work on the inner edge of the axle. you often get a ridge of rust built up just inside the bearing which keeps it from coming through. depending on the type of flanges ( hustler used several types over the years) you might also be able to split the bearing flange and cut the bearing off the axle.

[Dan67]

After removing the top finally...I dug in on everything else.
The stuck axle is the middle left side. The axle is stuck in the center bearing and want budge! I took a long punch inserted it from the opposite side and a BIG hammer and beat the heck out of it...still no budging. Has anybody got any suggestions on how to remove this stuck axle?

I had the exact same problem as you, but on the right middle axle. I soaked it in PB Blaster over night. I used a Gear Puller set from Harbor Freight 14 Piece Gear Puller Set to push the axle out. I liberally oiled the threaded rod of it and use a wrench to slowly turn it. The arms are made from cast steel and I placed them so that they hooked to the inner frame rail where the bearing flange is bolted to the frame. It took some time, but it got it free.

[arp35]

I have been there...done that. I ended up using a cheap harbor freights angle grinder and put a 3 1/2" cut off wheel on it and then cut through one side of the bearing enough to break it off the axle. Don't worry about saving the bearing or damaging the axle. The bearing is like 10 dollars and the axle is solid steel. Out of the 6 axles I had one that was slightly bent. Once you get them out check each axle for straightness. The bent one gave me an excuse to buy the HF 20 ton press which I used to straighten the axle. Anyway... just cut that bearing off. It will take all of 10 minutes.

[Dan67]

The HF 20 ton shop press is a must have tool. I used mine to push off all the old outer bearings from the axles, did not need to cut any of the bearings just pushed them off.

[Fatdog]

I got the grinder out with a small cut off wheel...All done! I'll remove the tranny tomorrow and out with the frame. I talked with a guy this past week thats going to sandblast the frame for me. I'll slap a great paint job on it then back in after the tub is clean!...