Picked up a Hustler not sure what model?

[john swenson]

beautiful work ...jboy

[Nortonscustoms]

My winter slow time hasn't really been a thing this year but I'm slowly pecking away at the 980 project.

Got the frame removed and begun cleaning/painting.




Tore the trans apart and rebuilt it.



All 4 mounting bolts were loose and 3 of the holes had broken bolts in them. Clearly the trans had come loose more than once. Extracted the broken bolts and Heli coiled all the holes. Decided to use automotive studs instead of bolts.



Welded 4 additional bolts to the lower part of the trans cradle and made lock plates. Even if the nut comes loose the stud is retained by the plate.



Also made 4 locking bars for the top of the trans as well. I'm pretty confident once everything is torqued down the trans should stay put.





While rebuilding the trans the sloppy nature of the trans shifting diamonds drove me nuts. So tapped and installed shoulder bolts along with a new support bracket and turned some delrin bushings. They rotate in their bores nice a smooth now without that tipping action.





Saw on this site some guys had made a twin stick arrangement and really liked the idea so made my own. The new shifter fits in the same location as the stock single lever.



Only required some minor mods to make work in the rear.



Got the new 23hp Vanguard fitted and motor mount, location, belts, ect sorted out. Hope to finish the parking brake and start turning the axles this week. Goal is late spring to have it all back together.

[mike lindsay]

Tremendous work! I have owned 2 Hustlers in my youth but never a 980. I would love to have one but it would have to be near complete. I do not have your abilities!!

[mike lindsay]

Some further thoughts a 980 with enough motor and addair tracks has to be near perfection!

[Nortonscustoms]

Slowly getting things done as time allows. The to-do list keeps getting shorter. Finished the new axles and sprockets along with a bunch of miscellaneous bits.

New heavy duty 1.25" axle next the original. Also changed the front and rear sprockets use two pins like the center sprockets. Found a couple broken pins under the motor mount which leads me to believe they were prone to breaking. Figure it wouldn't hurt since I'm putting a 23hp in it.





Some of the misc bits like the chain tensioner rollers. Steel sleeved then so they can spin free while tightened down.




My goal is to have to exhaust and motor ducting exit out the side like the original setup so a custom muffler will need to be made. The parts to make the muffle came in the other day.




I found a crack and small leak in the fuel tank....so that may lead me down another rabbit hole of mods.

[Noel Woods]

POR15 makes an excellent seam sealer that I've used on a couple aluminum and stainless fuel tanks. Check Amazon out, comes in a 4 oz. tube. I would also get some rust converter on that frame (water based product, roll on, brush, spray, dries black). The rust converter will last for years on its on. Can be painted over.

[Nortonscustoms]

Overall it cleaned up pretty well but there was some rusted spots so I ended up sandblasting the frame and painted it with Rustoleum 9100 which I already had. I use it on some of the machines I repair.

[Nortonscustoms]

The weather was nice out for once so was able to get the lower tub all cleaned up.



Got the new parking brake setup sorted out. Along with bilge pump and fuse box mounted.




Frame is back in the tub, slowly start getting it put back together.



The axle bearing flanges were sealed with globs of silicone. What is the preferred method? I see Richard's sells calk strips but am not familiar with that product.

[john swenson]

great work ! it looks really good . lots of area to ride from the picture ...jboy

[Nortonscustoms]

Reassembly is going smooth. I kind of forgot how much stuff is packed into the tub.




You really get to hone your skills with a magnetic pick up tool after the axles and chains go in...





To help control engine bay temps installed 2 cooling fans. The fans are controlled by a temp switch mounting on the motor.





After dragging my feet for a while I got around to making an exhaust. Ran the motor for a bit and I'm really happy with the sound. Quiet enough to keep the peace in town but a good throaty growl when stoking the coals.





Just waiting on heat shield material to box in the exhaust and some misc hardware.









The bottom half is pretty much done. Next the top half goes on the saw horses and start wiring lights/turn/brake signals, switches and gauges.

[Nortonscustoms]

Got the heat shielding finished up.



Mounted a 5.2" Spal puller fan where the little scoop is on the side of the body. Holysmokes does that thing move some air, fan is a beast for its size.




Since I already had to weld a leak in the fuel tank, went ahead and welded in a plate and added a fuel sending unit. Made a dash plate to mount the lighting switches and cover the zillion holes in the dash from previous owners. Added oil pressure, voltage and fuel gauges.



So that we can drive on the road added turn signals/ brake lights.



I got about 2 hours of run time on it now. So far everything seems to work perfectly. I hate the throttle response but that's to be excepted with the stock carb/throttle/governor. Next winter I'll throw a Mikuni on it and it'll be good to go.



Overall very happy with the way the old Hustler turned out. Still need to finish the exhaust port cover plate on the side of the body and a couple little things. New tires came in so hopefully I can get those mounted soon. Also need to dust off the vinyl cutter and make new HUSTLER stickers for the hood and body sides.

[argohunter]

This looks like a great restobuild! Nice work!!

[Nortonscustoms]

Thanks! It was a really enjoyable project. We've put several hours on it so far, what a fun machine! After I get the new tires on we'll head over to the lake by my shop and begin the sea trials..

[SiliconTi]

Wow, very nice job!

[dave phelps]

Very nice work!!! This machine was for sale near me in Illinois at one time. I have a 945 with new argo tires and it really scoots through the water.