Rotary Cutter Bush hog Model 2[emoji[emoji6[emoji640]2][emoji640][emoji640]][emoji6[emoji640]2] Deck Repair

[deerefan]

As the photos show, my deck is in bad shape. This cutter is 20 years old and when the rust/rot started it took hold fast. I have acquired some steel plate 1/8” to make the repairs. What is the best option to cut it? I do not have access to a torch, but do have a grinder with metal cut off wheels and can get my hands on a port a band. Thoughts? Any further advice on repair is definitely appreciated. Thanks

 

[newbury]

grinder with metal cut off wheels

And go back till you get to solid metal.
That looks like the mower my relative sold me, "just a little rust" as they say in Mississippi.
Repair required a welder. So I bought an Everlast 300 stick, for about $300.

 

[nctox]

I've cut 1/8th plate with a reciprocating saw, with metal cutting blade. Angle grinders can be quite useful as well. Otherwise, find a shop with a cutting torch.

 

[Chewwy]

With all that rot, it is likely structurally deficient. Unlikely patching the sheet metal will fix it.

 

[chim]

Heck, that's in great shape. I mean you didn't fall through it when you stood on it to take pictures

I refurbbed a couple RFM's. The five footer had some serious deck rust and the 90" had mostly baffle damage from rust. Both needed the "bumper bar" that runs around the front of mine (Caroni).

Start be removing everything that is bolted on and get the deck up on sturdy sawhorses. It's a whole lot easier when you aren't groveling about on the ground.

As mentioned, remove rusty areas back till you find solid material.

Cutting with a grinder is fine. The biggest mistake most people make it trying to use a cutting wheel like a circular saw. It will cut 10X the metal if you gently score back and forth just till the wheel breaks through. The weight of the grinder is all you want.

I cut some 10GA galvanized with my DeWalt 20V jigsaw and it went better than when I used my sawzall.

Cardboard templates are great to trim to shape and trace on the new metal. Cut slightly larger pieces that can be trimmed a little for the real fit.

Tack tack tack in different areas. On something long or wide I'd start in the middle and work my way out. Wirefeed is easier for me when doing lighter material. A REAL weldor could use stick

 

[deerefan]

Heck, that's in great shape. I mean you didn't fall through it when you stood on it to take pictures

I refurbbed a couple RFM's. The five footer had some serious deck rust and the 90" had mostly baffle damage from rust. Both needed the "bumper bar" that runs around the front of mine (Caroni).

Start be removing everything that is bolted on and get the deck up on sturdy sawhorses. It's a whole lot easier when you aren't groveling about on the ground.

As mentioned, remove rusty areas back till you find solid material.

Cutting with a grinder is fine. The biggest mistake most people make it trying to use a cutting wheel like a circular saw. It will cut 10X the metal if you gently score back and forth just till the wheel breaks through. The weight of the grinder is all you want.

I cut some 10GA galvanized with my DeWalt 20V jigsaw and it went better than when I used my sawzall.

Cardboard templates are great to trim to shape and trace on the new metal. Cut slightly larger pieces that can be trimmed a little for the real fit.

Tack tack tack in different areas. On something long or wide I'd start in the middle and work my way out. Wirefeed is easier for me when doing lighter material. A REAL weldor could use stick

Thanks! I have a 110v wire feed welder from Harbor Freight. I fancy myself a decent welder if I hold my head just right

 

[Jstpssng]

It's too bad that you don't live closer. I have a 5' BH deck which I plan to cut up to make a box blade. It's solid, but the blades and stump jumper are missing.

 

[deerefan]

It's too bad that you don't live closer. I have a 5' BH deck which I plan to cut up to make a box blade. It's solid, but the blades and stump jumper are missing.

Hey thanks. I acquired some steel plate from a Winn Dixie we are turning into an Aldi.

 

[chim]

Take plenty of pictures I took quite a few when I did the 90" deck, but can only find one from when I did the 5 footer. The 5 footer needed much more work. In addition to the baffles and solid round stock rub "bumper" on the front and around the sides, I also replaced top sections of the deck where the spindles mounted.

 

[John0829]

I rebuilt one a few years ago, a SideWinder that uses a tire for the drive, it was not in quite that bad of shape but after I finished I swore "never more". The more rot I chased the more I found even into the structural part of it that had to be replaced where it had looked OK.