Restoring Old Mower Decks (updated 4/2/06)

[MDB]

I have several 48" mower decks around here for B series tractors, all of them have at least one rust hole in them. Thought I would try a little restoration.

Top view before

Notice small holes and the rust craters.

Another underside view, more holes....

Starting to sandblast, wonder if there will be anything left?[:0]

Cleaned up pretty good, holes did not get any bigger....

Top view shows a few small holes

Looks like some welding to do here.

As thin as these old decks are I do not want to try welding patches over the rust spots so this is what I have decided to try.

This is what I have done so far, do you guys think this will work or has Old MDB went totally out of his mind this time?[:0]

[Kent]

Mike, As long as there's enough metal to keep it from flexing, I think the fiberglass will work OK. You'll have to build it up enough to give it strength, running the cloth in different directions, and finish it off with a heavy coat of resin...

[Guest]

Well I plan to do the same. Hope it works for you. I will probably time any fiberglass work with fixing a canoe I have.

[MDB]

Kent, I bounced those two decks around a little before I started working on them, they are surprisingly stiff for as rusty as they are. The third deck that I had was bad enough that I parted it out and threw the shell on the scrap truck.....

[D-17_Dave]

I'd think that as much grass and debris that passes the discharge shute that you'd have to patch the outlet and underside with metal. But now that we appreciate these tractors a little more the secound time around maybe they won't be subjected to such severe punishment.

[MPH]

Only thing i wonder about is how the fiberglass will stand up to abrassive wear? Admit it is a product I have very little experence with.

[johnmonkey]

How about brazing it with oxy/acetyline, lower temp than electric welding. It still would be good to see how well the fiberglass holds up. Just a thought. JH

[vfd702]

This is what I have done so far, do you guys think this will work or has Old MDB went totally out of his mind this time Hmmmmmmmmmmmm !!! having drunk gallons of coffee and some adult beverages with this guy.............. I vote OUT OF MIND !!!!!! hahahahahahaahahh looks good Mike ken

[mowerman1193]

I have patched several decks that was like that..I used a wire feed welder to fill in the holes and real thin pitted areas..then ground it down smooth..was alot of work but held up real well... Fiberglass is very strong and will probably work ok...however it is very brittle too...so if you hit a rock or something and it strikes the fiberglass it might crack or shatter it...Thats why I never used it and choose the harder way..It was alot of work to build up and grind down the deck fixed years ago and I am not to sure I would do it again..

[lboy1971]

I hope it works but from my limited experience with several Sears,Cub Cadet and JD lawn tractors with fiberglass hoods, a fiberglass boat and 3 corvettes I'm not to optimistic.

[dcw06]

I think you will be suprized at how well the fiberglass will hold up,if you lay in several layers of cloth.The cloth is what gives it the strength.Rough it between coats with your grinder or it wont stick to itself and will flake off.

[nighteye]

Looks like an excellent Idea to me. Keep us informed as the summer rolls on. I fixed one like it with JB weld when I was younger but never had a chance to see how it worked because it kind of got run over by a dozer. Ken

[B.Ikard]

Mike, I am seriously considering a sandblaster like the one in the picture and am concerned about having a compressor that will pull it. What size compressor do you have (cfm) and how does it perform? Also would be curious what media you blast with....I hear some use sand (cheap) and others splurge for the blasting media. Never blasted a lot and would welcome any suggestions. Brent

[comet66]

Fiberglass is pretty tuff stuff when layed in properly, so I wouldn't think it to be a problem structurally. However I think Marty's question is the key one. " Only thing i wonder about is how the fiberglass will stand up to abrassive wear?" I'd be sure to shut it off when crossing the driveway, etc.. I wonder if some of that spray on bed liner would extend the life of the plastic.

[MDB]

Brent, My compressor is a 80 gallon, two stage pump, 19 cfm at 175 PSI. I run the sandblaster at 125 and the compressor keeps up easily.

[Kent]

quote:

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Originally posted by comet66 I'd be sure to shut it off when crossing the driveway, etc..

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I'd agree with this recommendation. It's the abrasion of sand and small gravel that could cause problems. The resin used in fiberglass layers, like he's doing, is hard stuff but still subject to abrasion. Hand-laid fiberglass is MUCH different stuff than the "gel-coat" molded or "chopper-gun" sprayed stuff that you typically see...

[MDB]

Thanks for all of the comments, the mowing conditions around here will give this project a real test, lot of rough mowing and some driveways to cross. will probably have a good idea how it holds up by mid mowing season. I started out with three complete decks,took them all apart, threw one deck shell directly onto the scrap truck. Now I have two shells that I am rebiulding with fiberglass, putting in all new bearings and new roller shafts. Will post more pics later.

[MDB]

Here are a few pics that I took today, the fiberglassing is pretty much done and the decks are primed. I may smooth a few spots up with some resin......

[PhanDad]

Look pretty good me. Should give you a bunch of service years. You'll have to let us know how they hold up.

[PeppyDan]

Looks good Mike! If you feel you need more practice at the decks to make them perfect, I can trade you a couple rusty old decks I have laying around here, NO charge!(lol) Dan

[comet66]

They sure look good Mike, it's going to be interesting to see how the plastic holds up to the constant sandblasting.

[PatRarick]

I see a lot of concern as to abrasion, but something just occured to me. The decks rust out because grass clippings and residue collect in those areas and isn't cleaned off. If the residue stuck to those areas, it must be in an area where there is little to no abrasion problem. Or am I missing something? Pat

[Kent]

You are correct, Pat. I don't think abrasion will be nearly the problem it might appear at first. I think stress-cracks from the deck flexing might be the biggest potential problem... Many lawnmowers have used aluminum decks -- Lawnboy most notably -- and they held up to abrasion just fine. Fiberglass is probably about as "tough" as aluminum when it comes to abrasion...

[ZippoVarga]

We're all talking abrasion concerns and I just had a thought. I remember last summer of a topic suggesting undercoating. That rubbery tar like stuff that ziebart puts on to help prevent rust on the undercarriage of vehicles. Wouldnt this help? Or perhaps a good coating of duplicolor truck bed liner? Just a thought!! Sean aka Zippo

[IronPony]

Still need a smooth under side finish to let the grass discharge and as little as possible build up. Truck bed liner, seems to me, is a rough surface and would collect wet grass? Dan aka IronPony