My first mower build!

[Kaptain krunch]

hey everyone, new here and goin on my first mower build. Its a Servistar mower by Murray, i got it for free a long time ago because the mower deck was bent, and by bent i mean you could use it as a sea saw. Anyways, i used it as a utility vehicle for towing stuff and whatnot for a few years, till the ring gear finally stripped (cheap plastic), and there it sat for a good time with no hood or flywheel on it. A few weeks ago i pulled it out and started working on it, a few hours later, a lot of rewiring, carb cleaning, and a little bit of work to get the new ring gear on, and it started right up. Right now it idles fine but after 1/2 throttle it surges a lot, and when i choke it the surging stops for the most part, so i'm guessing its running lean. So far i've stripped it down a bit, done some de rusting, race prepped the tranny, removed steering (really sloppy, worst i've ever seen in a mower), and done a lot of rewiring.

Back is pretty rusty, but im planning on giving it a red/black paint scheme.

The engine is actually in really good shape, and the shroud is very clean since it was the only part that was kept inside

Nice cleaned out tranny, since this pick its been filled with 80w gear oil, a breather was made with an air filter, and its been reinstalled. I also welded the diff.

Started the new front axle, but no where near done (i ran out of hacksaw blades and got sidetracked). 8 degrees of KPI, 5 degrees of Caster.

I really dont like the hood, but maybe after a nice coat of paint it will be better.

Back end is pretty rusty, since this pic i've wire brushed it and given that area a few coats of black paint to stop the rust.


Here are the future plans, in the order they will happen:

-new steering setup, snowmobile tie rods, everything else custom.
-Hydraulic disc brakes, also from a sled.
-New front end, completely custom.
-Car head unit, with some 4" speakers. (maybe)
-ATV tires (if i can find a cheap pair)
-Pulley swap, looking for no more than 25-30mph top speed.
-Paint job, and other odds and ends.

Tomorrow im going to pick up another mower from a friend for 10 bucks, hes got 2 for me to choose from, ill most likely be using it for parts. He has a Wheel horse, 12hp, 6 speed, broken front axle, engine needs a little work. He also has a White, which he thinks will run with a carb cleaning and new battery, has no problems other than that, also a 6 speed, and 11 or 12hp. Im going to decide once i see what tranny each has, if each has the same tranny, then i'll decide on which hood i like better.

[Chris]

If you know anyone with a cub cadet, I'm looking for a transaxle. Mine had a catastrophic failure after I race prepped it. I kinda tightened a bolt down a bit too tight because I wasn't paying attention and BAM! :(

[Kaptain krunch]

Dont know anyone with a cub cadet that there willing to let go of, is it a special cub cadet model transaxle? I have a few off mtds (920s), a nice hydro from a deere, and a 700, but i may end up using the 700 in this mower, i think i might even have an 820 also, but thats on my grass cutter.

Do you know where i can find a 3/4 bore u joint for under $15? I cant seem to find one anywhere for under $40.

[Chris]

Dont know anyone with a cub cadet that there willing to let go of, is it a special cub cadet model transaxle? I have a few off mtds (920s), a nice hydro from a deere, and a 700, but i may end up using the 700 in this mower, i think i might even have an 820 also, but thats on my grass cutter.

Do you know where i can find a 3/4 bore u joint for under $15? I cant seem to find one anywhere for under $40.

It's a standard 900 IIRC, but it doesn't have keyed shafts, the wheels bolt onto it.

Have you checked mcmastercarr? Look at the "Links" section of our main page and there's some excellent links to places to get parts

[Kaptain krunch]

Man didnt even think of mcmastercarr, but sure enough that got what i need.
Posted on: May 30, 2009, 08:00:37 PMWell i went to get that mower today. Both were in good shape, the White had the exact same engine as my murry, and was virtually the same mower, but the wheel horse was much better built, and had a lot of nice features (hour meter, charge gauge, electric PTO, shifter on the column, and it looked nice too). It also looked like the Wheel horse had a peerless 820, but once i took the wheels off i noticed it had a 3/4 shaft, so no 820 turns out to be a 920. The shift keys and drum thing was rusted, but i took it apart and did about half the cleaning, and everything looks good except for first gear, its missing one tooth, but overall not bad. Also the front axle was broken off, he said it wasnt steering right so he gave it a hit with the sledgehammer  and it snapped right off, it was cast any ways so no worries on that. The seat is actually good, which is a first for any of my offroad mowers, or grass cutters. Its a wheelhorse 212-6, with a kawasaki 12hp. Not sure if it runs, but the engine looks nice and has good compression and whatnot, but it was sitting all winter without a oil drain plug so it may have a little rust inside.

I like the hood on this one better, and will most likely just make 2 offroaders, but build this one up first so that i have something to ride around on while i build the more difficult project.

Tires are the exact same as my murray, i have yet to see if they hold air.

I think thats the low oil shutoff? not sure.

This engine is much bulkier than my briggs 11.5



Thats where the axle snapped right off, it looked so strong, but i guess its just not.

Broken tooth on first gear of the secondary shaft.

I really like the shifter on the column, its got a cool feel.

all the cool little warning lights, most likely going to all be disconnected though.

Its got over 980 hours on it, seems like a lot for a mower to me

[Chris]

That wheel horse is REALLY cool!

If you need ant 920 parts, I have two with good internals, just busted cases :(

[Kaptain krunch]

Thanks, but if anything once this one goes im gonna switch it for my 700, theres a perfect hole already cut in the frame for one, ill get pictures later.
Posted on: June 01, 2009, 02:02:09 PMThis things got an electric pto, how durable are these? like would it hold up to the abuse of a go kart, i think an electric would be bad arse, plus i got a 16hp kohleer k series sitting around that needs a little work with the crank.

I also just noticed while i was resetting the hour meter, that its not connected to anything, so its got 983 hours + however many hours it had after the meter was unhooked.

[Chris]

Electric clutch? Kinda looks like a centrifugal?

[Kaptain krunch]

Yea, it was originally for the mower deck, its got 2 wires coming out of it.
Posted on: June 02, 2009, 01:02:10 PMI was also wondering if there is any place to order axle bearings for a 920? looks like theres a place for them just that there not there...
Posted on: June 02, 2009, 02:06:30 PMAnother thing, if anyone has or knows where to get a wiring diagram for a wheel horse 212-6 that would be great, this things got so many wires its confusing, and i know how to rewire it to a simple push button with separate kill switch, but i'd like to leave the hour meter, and ammeter, and its also got a 12v rectifier so i dont really want to mess with it haha.

[Chris]

We've discussed electric clutches on here before, you'll have to search to find the thread. You can order axle bearings directly from peerless, or you could go to your local lawnmower/small engine repair shop and they can order them for you (or you'll get lucky and they'll have them in stock). As for a wiring diagram, check out the contact info on wheel horse's website. I'm sure they'll eMail you one for free if you ask

[Kaptain krunch]

Thanks, i found the thread about electric clutches, i guess ill try to sell it and make a little cash.

As for the axle bearings, the reason I'm asking is because i found the parts diagram for this tranny, and it shows axle bearings and there is a place for them but i cant find the part number. I also have never seen a 920 series with axle bearings so i was wondering if you knew the part number for the right bearing from an online source.

And for the wiring diagram, I'm almost positive this was made before toro bought out Wheel Horse, so i cant find the diagram anywhere, and since wheel horse is technically out of business then i cant ask them.

[Chris]

And for the wiring diagram, I'm almost positive this was made before toro bought out Wheel Horse, so i cant find the diagram anywhere, and since wheel horse is technically out of business then i cant ask them.

They should still have all the technical data and stuff. Someone's gotta produce parts, which means they need to know those things; right?

[Kaptain krunch]

I guess, but i also couldnt find parts for it haha or any information really.  I'll try and find the ID tag on it and send them an email.

[Chris]

Yeah, you'd be surprised the stuff manufacturers keep, even after being bought out...

[Kaptain krunch]

Wow, i sent an email to them, and even though i did not have the right model number (it was missing a few) they told me there were two possibilities for which model it could be (1988 or 87), and on top of that there sending me in the mail a manual for each, free of charge! Now thats what i call great customer service.

[Chris]

See, I told you

[Kaptain krunch]

hey chris, or anyone for that matter, do you know how this part goes back in my transaxle? its a 920-010

Ok so does it go this way?

Or this way?




I also tried welding the front axle today, for testing purposed (dont worry wont do speed with stock front end). anyways, the welds came out horrible, and mine normally look decent, there really slag covered and not smooth, plus the arc looked really bad, it was a strange yellow.

This bead really doesnt look strong, i guess my 110 mig just isnt powerful enough

[AcreFarm]

Is that the cast iron axle?   If so you won't be welding that with your MIG.

[Kaptain krunch]

Its not cast iron, its cast steel (i think) either way i welded it and im gonna see if it holds up to some testing (jumping on it).
Engine runs though! started up first crank with fresh gas and runs awsome!

[Chris]

Yeah, welding cast isn't something your 110 MIG is going to like to do, hence the different colors and crappy welds. When I disassembled my 920 it looked like your 2nd pic.

[Kaptain krunch]

Got some of the steering parts, i got the 3/4 u joint from mcmastercarr, it was supposed to be $14+shipping, but i had them bill me by mail and they never send me the bill, so free u joint i guess. The flange bearing was $10 off ebay with free shipping. I still need a pillow block or something for the top of the shaft.

[Chris]

Free is always good!

[Kaptain krunch]

free is definitely good, now if i can just find a free sled engine for my go kart  . Just a quick question, for front end spindle brackets how thick should they be? i get free scrap flat stock from a local metal supplier, most of it is good but only 1/4".

[Chris]

1/4" should be plenty, but it all depends on your design

[Kaptain krunch]

using some square tube salvaged from a pair late 80's polaris trailing arms, going for approx 5* of KPI and 5* of caster. Not exactly sure of spindle size, since i have no idea of the tire's bore im using.

[Kaptain krunch]

Got the engine running right today, still need to tune the idle a bit, but for the most part it runs good. I still need to figure out if it has a bad magneto or my battery is just bad. This carb is really poorly designed, the idle adjustment screw is behind the carb facing the engine block, and it almost impossible to get to.

[Kaptain krunch]

Well she runs perfect now, and believe it or not the battery in there thats no more than 1 or 2 years old was bad, and the battery that was in my murray (8+ years old) works fine. So now it starts by itself and runs great. The only other problem is that it keeps blowing a fuse, im not sure what the fuseis for though, i mean it starts and runs fine without that one fuse. I'm guessing its for the PTO or headlights and the wires are just shorted somewhere.

[Chris]

The engine should run fine with no battery hooked up to it. From that and what you said about it blowing a fuse it sounds like you have an electrical problem somewhere. Not sure how yours is wired up, but on of my mowers had the ignition power (from the battery to the ignition) fused, and another had a fuse for the stator (between the motor and ignition). I believe the most common is from the battery to the ignition. I'dd pull out all the wiring and start from scratch, that's usually your best bet.

[Kaptain krunch]

I most likely what i'll do, this things got a mess of wires, it has 5 idiot lights, wires for electric pto, wires for headlights, seat safety switch, and transmission neutral switch, which is all almost useless to me besides headlights.

[Kaptain krunch]

Spindle brackets done, need the kingpins DOM tubing and a 5/8 drill bit to finish them. I also cleaned up the rims and checked the bushings, there pretty bad but im going to leave them for now.

[Kaptain krunch]

Front end is almost done, I got the spindle brackets welded onto the front axle with around 5* of caster and KPI, its not perfect, but **** it, its close enough, im not gonna be racing or going 100mph anyways. I also started the gas pedal, i want it to turn out something like this, i know it wont look that nice but im working on it.


Its not cleaned off yet because im not actually done, i still have to weld up 2 more spots i'm just giving my welder a break, its only got a duty cycle of like 40 at full amps.

Theres the start on the gas pedal, its taking forever because i have no pilot bits left, so im using a cheap black&decker skill saw, with a masonry blade to do all my cutting and grooving. and my angle grinder only has like 2 inches of grinding wheel left.

[Kaptain krunch]

Man seems like this forum is pretty dead? ah well, got some more done today.

Today i cut out the hood scoop, and bent it to shape, looks good but i think it could be a bit longer, i may try that. All the angles were bent with my ghetto press brake haha, two pieces of flat stock with the sheet in between, clamped to the table. I also got two new additions to the family, a $10 bench grinder, which has no power (you have to turn it by hand to get it started, then it gets up to speed, but has no power), and a $5 air powered paint gun. My air compressor also had something fail in it, i was running the air sander to get the hood ready for paint, when it made a leaking sound, i unplugged it, and it wasnt leaking so i think its something with the piston. I got the air compressor for free, because i was told it had piston problems, but it worked fine up until now.

Hoodscoop sitting on the hood, i think i would like it to be longer, but i really dont feel like re-doing it. Its made out of a washing machine hood, probably about 16 or 18 gauge steel.

Front view, i also have the hood all sanded down for paint, gonna be black with red racing stripes.

Paintgun

grinder, i'll have to take it apart and see why its so bad.

[Chris]

That's some good progress!

And yeah, this place is pretty dead - especially on the weekends!

[Kaptain krunch]

Starting to move a bit faster now, i decided i didnt like the way the hood scoop look, so i made an extension, its not perfect needs a bit more grinding to make it fit good, and maybe some epoxy but i like it better than before. Hoping to get the electromagnetic clutch off the engine today also (hope its not too rusted).

As you can see, the extension i made is a bit higher than the original so i'm going to have to do a little more grinding.

[Chris]

That looks good

[Kaptain krunch]

So a lil update, finished the steering shaft. I used the axles from my other 920 transaxle, and that u joint i got from mcmastercarr. I had to cut out keyway slots on either side of the u joint, and then tap for set screws, since i couldnt just drill all the way through the hardened steel axle. This thing was so soft that i could barely drill a straight hole through it (no drill press), so one side is tapped, the other has a hole, the i put a blob weld on the shaft inside the hole so it wouldnt slide.

I tapped 1/4" holes at first, but they stripped out so i tapped a 1/4" NPT hole and that worked much better.

I'll have to use some clamps or something to keep the keyways in there. Overall though its a very strong setup, so hopefully it will work well. just need to figure out how to get the stock steering wheel on this shaft.

[Chris]

Not bad

[Kaptain krunch]

Are there any rules on home made mufflers?

[Chris]

As long as it incorporates a USDA Forest Service approved spark arrestor and isn't obnoxiously loud, no.

[Kaptain krunch]

And where would i get an approved spark arrestor? its not very loud, i designed it somewhat like a car muffler, using baffles and whatnot.

[Chris]

Most OEM ride-on mower mufflers are, along with tractor mufflers and of course; ATV mufflers

[Kaptain krunch]

Was hoping i wouldnt have to tear open the stock muffler...i may just clean out the exhaust port and leave it as is then, not sure.

[Kaptain krunch]

Did a little more work. I havent been able to do much, im dog sitting and this dog is ****ing attached to me, i walk to the bathroom, she gets up follows me, then waits for me at the door. I get up to get a drink of water, follows me. I go out to the workshop for half an hour, she waits at the door, standing up the whole time, and if im out for too long she starts to scratch the door... anyways.

I made the little arm that is attached to the end of the steering shaft, i have no idea what its called. Anyways, i took a piece of flatstock, drilled a 3/4 hole in it, then welded bushings from front mower tires to it, i tapped each bushing for a 1/4" bolt, which will go into the keyway to stop it from turning on the shaft.

I drilled quite a few holes, cuz i wasnt sure the exact length.

The bushings were steel i think, but they were so soft, it must have been the easiest thing to drill through besides wood.

The 1/4 bolts i used, i ground the threads at the end so they dont get messed up.

[Kaptain krunch]

Took a trip into Rutland today to get some DOM tubing for my spindles. They want $9/ft for 3/4 id DOM tubing! i said f$#^ that and went to home depot, got some 3/4 bolts and went home. I had some extra rear rims lying around, so i cut out the centers, perfect 3/4 bore and very thick walls, perfect for spindles. I have to remake the spindle brackets, but im not complaining.



I have to clean them up, but they seem perfect.

I also got the electromagnetic clutch off FINALLY. The thing was so rusted on, I actually thought it was threaded on, so i had a bar on the flywheel, and my pipe wrench with another bar on the clutch, i was fighting myself thinking it was just really rusted...I finally put down the stupid thing and the clutch just fell off...I felt pretty retarded.


Oh yea, and a month later mcmaster carr finally called me asking for $20
for the stupid u joint, which isnt worth $10, but i already drilled it and whatnot so now i guess im stuck with paying for it, they already sent me the invoice to my email...
Posted on: July 06, 2009, 02:08:33 PMI decided i was going to paint my tins (purple and gold theme), so i went out and started stripping all the tins off, and man am i glad i did, EVERY single fin was clogged with leaves and dirt, i dont see how this thing could have stayed cool. So its all cleaned, and im gonna start painting soon. Should i use high heat paint for the tins?

[Chris]

Man I need to work on something...

Normal paint should hold up fine for the shrouds, I have $.98 wal-mart special flat black paint on my 18 opposed

[Kaptain krunch]

Well this is going on hold for a while, were moving in a few weeks, and i gotta pack up my workshop before the landlord flips about how i ruined her garage and whatnot. I painted the engine and the hood, im happy with both but im not exactly sure why i didnt paint them with the same color scheme. I also made a support bushing for the bearing, because pillow blocks can move in there mounts, and that would mess up my steering.



It looks pink, but its actually a nice glossy red, not sure why the camera picked it up as a pinkish color.


Support bushing, this will be welded to the frame, and then the bearing will bolt onto this.



I'm also getting a free dirt bike sunday, so maybe ill get up a thread about that, I'm phsyched!

Chris, i may end up putting the bike engine in my kart, if i do i'll let you know.

[Chris]

Free dirtbike? I want a free dirtbike

[Kaptain krunch]

its a 1970's ts185, but its still free haha.

[Chris]

That's cool, I have a 1981 XL100s

[Kaptain krunch]

Nice, those old hondas were very reliable, and the 100's are just plain fun to play around on, wish i never sold my DR100.

[Kaptain krunch]

Well i got it, and with a bit of pre-mix in the cyl in started up second kick! i need to either buy or make up a throttle cable (oil injected so it has to go to carb and injector), get some injection oil, 20w40 for the tranny, and a container of some sorts for the oil and then it should be drive-able!




I got the gas tank too but its ugly as sin.

So how about a shifter-mower ? 

[Chris]

That's awesome

[Kaptain krunch]

Well i got my hopes way up, but it needs more work than i thought. It needs a new gear insert thing for the clutch (hard to explain, but i cant disengage it without the part), new oil injector pump, and a new $20 throttle cable. Plus, while fixing the clutch i noticed how bad the crank bearings sound, there very scratchy. So i think i may just run it on pre-mix, till the bearings go, i dont feel like putting a whole lot of cash into something thats gonna die soon anyways.

[Chris]

Part it out

[Kaptain krunch]

Yup, its up on c-list for $100. If it doesnt sell ill beat the hell out of it without a clutch, or seat until the crank bearings go, then sell the electronics.

[Kaptain krunch]

So im getting a free pair of headlights for this thing from a guy in CT, hes sending them to me for free, very kind. I'm also considering going with a live axle and using my 700, right now it would be a pain to set up good brakes on this transaxle. I'm just not sure i want to spend the money on tires, rims, bearings, and an axle.

[Kaptain krunch]

So im back at it, got another mower with an 42 ci opposed twin and 820! both are going in the WH and both are in good shape. I also tore the whole mower down, started making dash supports, unbent the frame and welded some cracks. Just ran out of flux core wire today so cant do much more...

This is the stuff im making the dash support with, its pretty thick, was a sled bumper.

bare frame

The only problems with the engine were a gas tank and carb full of rust and water, and the starter needed brushes, runs like a champ now.

The hood isnt in the pic, but ironically this mower was just a bigger version of the first mower i was planning on building (the servistar).

[Chris]

The opposed twins are real workhorses. I have about 5 of them

[Kaptain krunch]

 

5, man i only have 2...but ones a horizontal shaft, so maybe go kart some day?

Anyways, i think for the mower I'm gonna have to break down and buy a $40 u-joint, mcmaster wants theirs back and I'm not willing to pay $20 for it (really crappy). I wish the junk yards around here would let you pick your own parts...its a real bummer.

[Chris]

You have a horizontal shaft opposed? What size?

[Kaptain krunch]

Its a 40ci 16 horse, using it to mow my lawn now, but once i fix up the JD it may go in my kart.

[Kaptain krunch]

Man, i cant get the flippin tires off this transaxle! I have tried everything, there so rusted. I've used a sled hammer, heat, tons of wd40...anything else to try? i know a puller wont work if a sled hammer and all my strength wont do anything. I think i might just have to cut the rims off...

[Chris]

You might have to just get a different transaxle and sell that to someone for a grasscutter. I tried everything to get the wheels off my cub cadet, and all I ended up doing was breaking tools

[Kaptain krunch]

I would really rather not pass up a perfectly good 820, maybe i'll bore out the differential gear's holes and get a 1" kart axle. Or i could just cut the rims off these axles.

[Kaptain krunch]

Well, i was really putting off work on this thing, because of all the problems i ran into, now this whole project is getting put off for a while. I recently picked up a old 400cc twin cyl motorcycle for $40 and got it running, now i've ripped apart my go kart and im putting that engine in there. Anyways, the shop (my porch) is completely taken up by that project. I promised myself i would get back to this one sometime though.

[Chris]

Well, i was really putting off work on this thing, because of all the problems i ran into, now this whole project is getting put off for a while. I recently picked up a old 400cc twin cyl motorcycle for $40 and got it running, now i've ripped apart my go kart and im putting that engine in there. Anyways, the shop (my porch) is completely taken up by that project. I promised myself i would get back to this one sometime though.

That's awesome