Cushman truckster

[Tom O]

Put a bicycle carrier on the back for your penny farthing!

 

[Alexander]

Here is a picture what it looked like before dustless blasting.

And about 50 minutes later I had a clean starting point to paint the cushman.

Dustless blasting is nothing short of amazing. You mix water in with the media and there is no risk of warping sheetmetal because the water cools the metal while you strip it. Also clean up is easy. I just rinsed excess sand out of all the cracks with a regular pressure washer. After media blasting I acid etched the metal and let it sit overnight. The next day I put on a thick epoxy primer. The day after that I hand sanded and sprayed it with enamel paint.


Now I need to install the engine for the last time and wire it.

 

[Tom O]

Looks good!

 

[Alexander]

I had to patch a few rust holes. For material I went to steel inc. The company is under new ownership. The new owners were very friendly and have a plan to add cold rolled stock to there inventory.

 

[Alexander]

I bought a wiring harness from Painless Wiring and got that installed. I regretted throwing the old wiring harness almost immediately. This one is going to be much more reliable so I guess it is better that I decided to replace everything. But wow that was allot of work.

 

[kevin.decelles]

I can’t believe that’s your garage. Good job fitting that in there


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[Alexander]

Thanks. I think

 

[kevin.decelles]

Last time I was there we barely fit in the doughnuts from Tim’s




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[Tom O]

That’s hot a bad setup who needs a workbench when you can put a piece of ply on the Cushman!

 

[CalgaryPT]

But wow that was allot of work.

What a great project. That looks like so much fun. Keep going please

 

[Chicken lights]

I bought a wiring harness from Painless Wiring and got that installed. I regretted throwing the old wiring harness almost immediately. This one is going to be much more reliable so I guess it is better that I decided to replace everything. But wow that was allot of work.

I HATE fixing old wiring. I did my engine harness about a year ago, just dropped in a new one. Fixed so many issues for me, but you’re right it’s time consuming

 

[Tom O]

Years ago a bud had a 850 Norton that needed wiring I spent the morning making him a stock wiring harness making sure to wrap all of it, nearing completion I went for some lunch and found another buddy had come over cut out my wiring replacing it with “ well this is all you need “

 

[Alexander]

I got the wiring done and took this thing around the neighborhood for a test drive my initial impression is the engine is a lot better suited to the task. The engine is a 610cc v twin. Commonly found in generators, pressure washers and farm equipment. It is meant to be a stationary engine but i removed the governor and welded a simple 2 into one exhaust similar to a motorcycle. Now I need to put all the other small parts back on. In the meantime the machine shop i work at made drawings to reproduce the doors for this. Not sure how i will source the door handles yet. Any ideas?

 

[CWelkie]

Very nice work on the restoration / re-fit!
About the door handles ... they wouldn't be OEM but the first thought in my head was for RV (i.e., trailer) door handles. They are flush fitting with locks. They are suited to rather thin doors and may be adaptable and useful.

 

[Alexander]

I finally got some door parts made. the white door on the truck is the original. The shiny one is a new door skin from the sheet metal shop. They copied it exactly. I still need to actually build the door frame. But the hard part is done.

 

[RobinHood]

That is a nice looking door shell, Alex. Good luck with building the frame.