Work Horse GT1600 restoration and conversion to Hydro

[cleat 6,697]

Choke cable ready to install.

 

Choke cable mounting nut tightened.

 

Choke cable installed choke open.

 

Choke cable installed choke closed.

 

[cleat 6,697]

Throttle cable ready to be installed.

Tension bolt tightened to hopefully the proper amount.

 

Throttle cable installed.

 

Dash showing throttle and choke cables installed.

I will install the throttle knob later.

 

 

[cleat 6,697]

Belt guard upper bolt, push nut, washer, lockwasher, nut ready to install.

 

Belt guard upper bolt installed and held in place by push nut.

 

[cleat 6,697]

Throttle knob installed.

 

[cleat 6,697]

I pulled and covered the choke cable with a protective sheath of thick walled heat shrink tubing.

Thanks to Bill D for this suggestion.

 

I added a couple of layers of heat shrink where cable rubs the hood stand for protection.

Also installed a better nut and a star washer also suggested by Bill D.

 

A piece of smaller thin walled heat shrink used to help seal the open end of the cable.

 

 

 

[ebinmaine 68,855]

Nice small extra touches make all the difference.  

[cleat 6,697]

Fuel hose installed.

I used plenty of clips to hold it in place and space it out slightly from the engine to help with heat soak issues.

 

[cleat 6,697]

Fuel tank ready to install.

Bolts shown are too short.

I ended up using 5/16x3/4" bolts, lockwashers, and flat washers to get correct thread engagement.

 

Fuel tank partly installed.

 

Fuel hose connected to shutoff valve and bottom bolts installed into fuel tank.

 

 

 

 

Edited December 16, 2024 by cleat

[cleat 6,697]

Hydraulic oil filter installed.

Fuel tank lower bolt right above filter must be installed before filter is installed.

Rear axle has been filled with oil prior to this filter being installed.

 

[rick 237]

Very nice work, Cleat!

No plan to add studs to the rear hubs, or are you keeping it stock?

[cleat 6,697]

Fuel tank treated with back to black.

 

[cleat 6,697]

3 hours ago, rick said:

Very nice work, Cleat!

No plan to add studs to the rear hubs, or are you keeping it stock?

Studs are in the works.

[ebinmaine 68,855]

1 hour ago, cleat said:

Studs are in the works.

 

Excellent 

[cleat 6,697]

PTO pivot plate assembly ready to install.

 

PTO pivot plate assembly installed and torqued to 26ft/lb.

 

PTO clutch plate and bearing race ready to install.

 

PTO clutch plate and bearing race installed using a little blue loctite on the bolt threads.

Bolts torqued to 96in/lb.

 

[cleat 6,697]

PTO hoop ready to be installed.

 

PTO hoop installed.

I used a 5/32 cotter pin instead of the hairpin clip at the bottom of the hoop.

For the trunnion I used a thicker washer under the hairpin clip to eliminate excess play.

 

[953 nut 56,150]

This is such an amazingly detailed thread from start to finish.                      You have done such a great job of showing each step, it needs to be saved as a  tutorial on here.

[cleat 6,697]

PTO grip installed.

I did not have a new one here so I used the best one I had on hand.

 

[davem1111 2,050]

27 minutes ago, cleat said:

PTO grip installed.

I did not have a new one here so I used the best one I had on hand.

 

 

 

If you're referring to the rubber/plastic grip, I think I have several new ones in my NOS parts box....  I haven't had time to try to list and sell a lot of stuff.  Happy to contribute one to this project if you'd pay for or split the shipping cost...   

 

Beautiful restoration work - I'm enjoying following along, as I'm sure many here are. 

[cleat 6,697]

4 minutes ago, davem1111 said:

 

If you're referring to the rubber/plastic grip, I think I have several new ones in my NOS parts box....  I haven't had time to try to list and sell a lot of stuff.  Happy to contribute one to this project if you'd pay for or split the shipping cost...   

 

Beautiful restoration work - I'm enjoying following along, as I'm sure many here are. 

Thanks for the offer.

This rubber grip looks OK so I will be good for now.

Whenever you go to list NOS stuff, please let me know what you have.

Thanks, Cleat

[cleat 6,697]

Front fender bracket ready to install.

I am using a couple of large fender washers under the hoodstand for support to help prevent it cracking there again.

 

Front fender bracket bolted to hoodstand.

 

Front fender bracket bolted to hoodstand showing support washers underneath.

 

Fuel tank bolted to front fender bracket.

 

Front fender bracket was measured to be square and even so fender and seat will bolt on properly.

Front fender bracket has slotted mounting holes to allow for proper fitment.

Front fender bracket measured to be square to hoodstand Left side.

 

Front fender bracket measured to be square to hoodstand Right side.

 

[cleat 6,697]

Some previous owner decided to drill a hole in the side of the dash console so I decided to square it off and install a carriage bolt.

I could have had it welded in but decided this would work just as well.

 

Here is the hole.

 

Bolt installed.

 

[cleat 6,697]

Hydro cooling fan ready to install.

 

Hydro cooling fan installed and bolt torqued to 84in/lb.

 

[Handy Don 12,634]

1 hour ago, cleat said:

ome previous owner decided to drill a hole in the side of the dash console so I decided to square it off and install a carriage bolt.

I could have had it welded in but decided this would work just as well.

That's a great puzzle to pass on to any future owners, for sure!

[cleat 6,697]

Wire harness as pulled from tractor.

 

I made up a bracket to secure the sealed fuse holders from a scrap piece of aluminum that was kicking around the shop.

It is drilled on each end to be mounted using two existing bolts that hold the front plate.

It was then drilled and tapped so I could screw the fuse holders to it.

 

Fuse holders labelled.

 

This is the kit I used to make up the fuse holders.

 

Wire harness at mid rebuild.

Harness has been very modified to support the upgraded charging system, fuel gauge, tail lights.

 

Wire harness ready to install.

 

 

[cleat 6,697]

PTO switch ready to install.

 

PTO switch installed.

This is a change from the old style switch that the Work Horse came with.

Old switch that was removed.

 

PTO switch installed.

 

Edge trim installed on bottom of front plate to protect wire harness.

 

Wire harness installed.

 

Wire harness connected to engine alternator and magneto.

 

-Battery cable installed.

 

Wire harness completed at fuel tank sender and tail light connector.