400 restoration project

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400 restoration project

Postby Barrie2777 » Wed Dec 02, 2015 5:03 pm

Last week I yanked this one off the shelf for restoration. If you look beyond the dust, you can see it is straight and without dents. The front of the decking was bent badly so I cut it off.
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Re: 400 restoration project

Postby Barrie2777 » Fri Dec 11, 2015 8:01 pm

For the first time ever, I sent the big parts out for sand blasting. Gone for two days and back beautifully blasted and ready to prime. $150
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400 base.JPG
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400 parts primed.JPG
400 parts primed.JPG (36.47 KiB) Viewed 4026 times
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Re: 400 restoration project

Postby Barrie2777 » Sat Jan 02, 2016 5:44 pm

Due to the lack of good functioning brakes, most HUS-SKIs have the front tin smashed and the two support elements underneath are usually missing or cracked or bent(usually all of the above but in reverse order.) The understructure on this 400 is perfect despite a bent of front tin section. I am posting these photos for those who need to see how these parts are supposed to be.
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400 front close-up.JPG
400 front close-up.JPG (38.34 KiB) Viewed 3975 times
400front close-up #2.JPG
400front close-up #2.JPG (39.72 KiB) Viewed 3975 times
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Re: 400 restoration project

Postby Barrie2777 » Sat Jan 02, 2016 5:47 pm

I fitted the front tin section then located where the chain guard side will be attached to this tin. This should be done before you weld the tin in place because there is not enough room to drill the holes in the proper place if you try to do this after welding the tin in place. Take note of the short piece of angle iron on the chain guard side. This is where the spring for the brake actuating lever is attached.
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chain guard placement.JPG
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Re: 400 restoration project

Postby Barrie2777 » Sat Jan 02, 2016 5:51 pm

I weld on the offset nuts before I attach the front tin only because it is easier. There is lots of room to weld them on later. They are welded on to the underside. Welding on a nut is also an option.
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offset washers welded on.JPG
offset washers welded on.JPG (29.33 KiB) Viewed 3974 times
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Re: 400 restoration project

Postby Barrie2777 » Sun Jan 03, 2016 12:06 pm

With the front tin clamped in place I then hammer the front edge around the bumper pipe. You can see where the old weld was cut and this new piece is going back to the same spot.
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front tin clamped in place.JPG
front tin clamped in place.JPG (42.47 KiB) Viewed 3955 times
formed edge.JPG
formed edge.JPG (31.59 KiB) Viewed 3955 times
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Re: 400 restoration project

Postby Barrie2777 » Sun Jan 03, 2016 12:22 pm

The hood for this 400 was found on a 444. Unfortunately, one of the previous owners did some cutting and welding to modify it for his machine. I will have to reverse all his efforts. The removal of the metal blocking the clutch hole will be easy. The right side was cut away and dented so this will have tobe fixed. I cut a piece large enough to fill in the side and remove the dents at the same time. Clamping it in place then cutting around it , using the piece as a guide, ensures a good fit.
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repair need to hood.JPG
repair need to hood.JPG (29.29 KiB) Viewed 3955 times
new piece clamped in place.JPG
new piece clamped in place.JPG (30.07 KiB) Viewed 3955 times
new piece fitted.JPG
new piece fitted.JPG (29.67 KiB) Viewed 3955 times
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Re: 400 restoration project

Postby Barrie2777 » Sun Jan 03, 2016 5:08 pm

When all the parts are repaired I put the machine together to make sure 1- all the parts are there (including all necessary bolts, nuts, washers) and 2- they fit! I have one more thing to correct on this machine. Someone with sharp eyes should be able to see what part doesn't belong to a 400???
Attachments
400 rt side.JPG
400 rt side.JPG (37.98 KiB) Viewed 3946 times
400 left side.JPG
400 left side.JPG (38.16 KiB) Viewed 3946 times
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Re: 400 restoration project

Postby myoldhus-ski » Sun Jan 03, 2016 8:16 pm

I would guess the bent up handle bars. Jim Warburton
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Re: 400 restoration project

Postby Jano » Mon Jan 04, 2016 10:09 am

My guest is the hood latch. Seems to be a 444 on first picture and not there on the second picture.
Jano
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