Bolens Diablo Rouge and Hus Ski Discussion Forums

This assembly is pretty much all brand new. New bearings, sprocket, brake disc,spacers,jackshaft , woodrufff key, and rebored salsbury clutch. The rest of the clutch was in good shape and the aluminum casting was nice. Cleaning and new paint on clutch.

All I can say is WOW!!

Excellent work Randy. Do you you know how the splines were machined? For example, did he use a shaper and grind a tool to the correct profile, or a milling machine with a pre-made cutter that was the correct profile or some other method? I'm a very, very amateur machinist and interested in how things like those splines are cut.

The machine used was a gear hobbing machine. It has special cutters that match the shape needed to be cut. I haven't personaly seen the machine yet. After I finish my 444 I want to check it out myself. I have been a machinist for 30yrs and wouldn't attempt cutting them any other way. This old boy doesn't let to many people in his shop, but he is someone I know from a previous job and we are getting to be good friends. If I can take some pictures of these machines eventually, I will post them for you. I do know he has a large inventory of cutters which he tells me are very costly. Luckily he had the one for the jackshaft. I did make up 6 extra shafts, but I'm going to run this 1st one in my 444 to test it out before I would let any others go.

Thanks for the info. I always like seeing how different people go about making or repairing parts for these machines.

I had to make a new carb. mounting plate for my brothers 1965 hus-ski 600. It was cracked so we decided it was time for a new one. He is Mark (1965 Hus-ski) on the forum.
I make all my parts with a manual Bridgeport Mill adapted with a new digital readout and powerfeed. I also use a manual lathe.

Getting my parts together for the seater. It was in rough shape. The frame was good and I saved the backrest arms. Had to make new ski mounting brackets, skis, coupler piece to ball joint, seat and backrest. I bought the toe clips from Barrie and the ski runners from Bruce. Also got lucky and found a new taillight assembly,my old one had many rust holes completely thru it.
I made a pattern for the seat and backrest from my brothers 600. The skis a friend made for me, he is an awesome woodworker and steamed the maple skis plus laminating UHMW to the bottom.

Been working a long couple months on the metalwork for the frame/chassis assembly.Finally finishing up that with the handlebars,seater and hood.
Here are some pictures of the hood.

Feels good to finally be ready for paint. Many hrs as you all know.

I'm not a painter so I have a local shop helping me out.