400 restoration project

Barrie2777 · Post by **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.

Barrie2777 · Post by **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

Barrie2777 · Post by **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.

Barrie2777 · Post by **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.

Barrie2777 · Post by **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.

Barrie2777 · Post by **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.

Barrie2777 · Post by **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.

Barrie2777 · Post by **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???