1983 Hustler 950 V-twin transplant

[Stonewall]

Well, since I finally got myself motivated to start back to work on this, I thought I'd post up a new thread to show how I'm putting it all together. I decided that the little 16 HP flathead motor wasn't enough, so I found a pretty good deal on a used Kohler Command 20 to put in. I also have new 94c Duster and 780 clutches to put in.

I got my T-20 back together today, and hopefully I've sloved the leak problem. I took the plungers to the machine shop, and had 2 more o-ring grooves cut into them, so I now have the first triple o-ring plungers... Even though the guy didn't get the spacing right, I think they'll work fine...




I made brackets and put in Max II chain adjusters for the rear chains, so hopefully that'll save some headache.




I rebuilt the stick mounts, and made them more robust.





Tomorrow I will start on the T-20 bracing and making a split shift setup. Then I have to make a new engine mount plate. When all the fabrication work is done on the frame I will have it powdercoated.

I'd like to find a nice 980 lower before then so I can convert to a Bigfoot, but if not, I'll just go with the 950.

I'm also looking for a factory roll cage if anyone has a line on one of those.

[cclingma]

Wow, you're going at it. I'd enjoy seeing some pitures of your MaxII chain tensioner setup if you find yourself wanting to post pictures.

Oops. Just looked in your gallery and saw pics of the setup. Looks nice and thanks for sharing pictures.

[Stonewall]

Wow, you're going at it. I'd enjoy seeing some pitures of your MaxII chain tensioner setup if you find yourself wanting to post pictures.

Oops. Just looked in your gallery and saw pics of the setup. Looks nice and thanks for sharing pictures.

Did the pictures not show up in my post? I can see them, I used Photobucket so they'd be nice and large....

[LarryW]

Yea pictures showed up great. Nice work! Those triple O ring plungers should never leak! Hopefully the MaxII chain adjusters work out well for you.

[jpswift1]

Yep, the pics showed up. Great work, excellent ideas! I might have to copy you......they say imitation is the best form of flattery. It looks like you're really making that Hustler a truly reliable machine. Next, you might want to reinforce the T-20 cradle with some extra steel so it doesn't work its way out.

[Stonewall]

Glad y'all can see the pictures. The Max adjusters work good on the table, so hopefully they'll do the same when it's all together. I started reinforcing the the T-20 mounts today. I have some flat steel tack welded onto the existing mounts to strengthen them, which I'll weld up when I get the mount slots in the right places, and I'm making some upper mounts with 1" angle. I'll post up some pictures of that tomorrow when I finish it. Feel free to copy whatever you like from my upgrades, hopefully some of y'all can see it in person a Busco (provided I make it )

[micmac]

Stone,

Looking at the picture of your plunger...is it possible that the most inner O ring will go inside the case? If so it probably won't last too long. Even if it does it shouldnt hurt anything as the other two should be fine.

[Stonewall]

Stone,

Looking at the picture of your plunger...is it possible that the most inner O ring will go inside the case? If so it probably won't last too long. Even if it does it shouldnt hurt anything as the other two should be fine.

These were origionally single o-ring plungers, and the most inner one is the origional location. It won't be gettting pushed into the case, because the plunger hits the drum before it goes that far.

[Stonewall]

I got my transmission mounts mostly finished, (my pictures were taken Friday...) and I'm almost ready to start on my split shifter setup. I'm still in the process of thinking of the best way to make it work.

[Stonewall]

Didn't get a whole lot done today. I finished drilling the holes for the transmission bracing. I was trying to work out how to do my split shift, and got frustrated with the crappy cobbled together floor area under the seat frame. So I cut the whole floor out and I'm now in the process of making a better one. I built a new battery tray, and tomorrow I'll put together most of my shift linkage, but I can't finish it until I find some heim joints... I can't believe how hard it is to get heim joints...

[cclingma]

Very nice! I'm the goof that said I couldn't see the pictures. Must have been because I was trying to view this sight on my phone. The pictures are awesome now that I'm at the computer. Thanks for sharing!

[Stonewall]

Thanks! Glad you can see the pictures!

[Stonewall]

I made a small amount of progress today. I finally decided how I'm going to build my split shift linkage, but it won't be complete until I get my heim joints from McMaster-Carr. I did however build the shift levers and the bracket that will mount them. Progress is slow, but hopefully I'll be able to bring it to Busco...

Pictures:

Out with the old,


in with the new...



Shifters

[LarryW]

Lookin Good!

[Stonewall]

I finished the split shifter today! It's a somewhat complicated setup, but it works great. I'm not sure how well y'all can see how it works from the pictures, but I took lots from many different angles, so hopefully y'all can make something out of it...

The elusive Heim joint....
\

This is the starting point:




The right side:





The left side:





The whole thing:



I designed this shifter to run along the side of the tub, out of the way of the rear floor, just like the origional, but on both sides.