This is the 1977 Cushman Truckster that I drug home a few years back. It is nearly done, finally, but through the build process, I never posted a Build Thread. So if there are any 3 wheel fans out there...
IMAG0365 by Ben Modified, on Flickr" />
IMAG0366 by Ben Modified, on Flickr" />
IMAG0367 by Ben Modified, on Flickr" />
IMAG0363 by Ben Modified, on Flickr" />
IMAG0364 by Ben Modified, on Flickr" />
This is what I hoped it would look like eventually
Drawing by Ben Modified, on Flickr" />
I started by extending the original Cushman frame. I used the Cushman front fork with trailer springs in the back suspending a UTV style Spicer rear axle. The axle has an 11.5:1 ratio which I have stepped up thru a jack shaft. Goal is a crusing speed of 50 mph. The rear axle has a built in forward, neutral and reverse and at the pull of a lever will lock the diff into a spool.
IMAG0362 by Ben Modified, on Flickr" />
IMAG0396 by Ben Modified, on Flickr" />
I originally intended to use side by side seating but eventually went with an inline motorcycle style arrangement.
I bought a Honda 20 hp V twin for 1/2 price at a Northern Tool close out sale. The power went thru a Comet Clutch that I had sitting on the shelf, then thru a jackshaft and temporary chain to the axle.
I split the cowl to make it wider and started fabricating a door hinge arrangement to support Suzuki Samurai Doors.
IMAG0548 by Ben Modified, on Flickr" />
I built a roof structure using 1" tubing and 18 ga steel panels for a roof skin.
IMAG0571 by Ben Modified, on Flickr" />
IMAG0573 by Ben Modified, on Flickr" />
IMAG0574 by Ben Modified, on Flickr" />
Somewhere along the way, I upgraded from 8" wheels to 12's using trailer tires on the rear and a scooter tire up front.
IMAG0682 by Ben Modified, on Flickr" />
Also upgraded the front drum brake to disc. I used a nos disc from an early 70's electric Citi Car. As it turns out, Citi Car sourced the disc from a Cessna, so yes, it has an airplane front disc brake. Made up a simple bracket and adapted a sportbike brake caliper to it.
IMAG0719 by Ben Modified, on Flickr" />
Rolled some beads in some more sheet metal and made the floor and the back wall of the cab.
IMAG0688 by Ben Modified, on Flickr" />
IMAG0691 by Ben Modified, on Flickr" />
IMAG0694 by Ben Modified, on Flickr" />
More bead rolling would yield some bed sides. Also utilized the original tail gate.
IMAG0706 by Ben Modified, on Flickr" />
Once the bulk of the fabrication was done, I rolled the assembly over to finish welding the underside more easily.
IMAG0716 by Ben Modified, on Flickr" />
I then added a few small trim pieces to blend the lines of the doors into the cowl
IMAG0775 by Ben Modified, on Flickr" />
I didn't really care for the look of the front so I cut out the original sheet metal and welded in a new wheel opening.
IMAG0776 by Ben Modified, on Flickr" />
IMAG0777 by Ben Modified, on Flickr" />
Being a huge fan of the Safari Windshields in my VW's, I formed a windshield mounting area and used one side of a tilt out windshield from a 5 ton military truck. The frame w/glass was made in Korea as a direct fit for the 5 ton except that it used metric fasteners.
IMAG0778 by Ben Modified, on Flickr" />
IMAG0820 by Ben Modified, on Flickr" />
As I mentioned at the beginning of this thread, it is nearly done at this point. I have decided to rubber mount the engine to reduce vibration from the v twin. When that is complete, I have already cut some aluminum tread plate to fit as a bed floor. A small bit of body filler here and there, some paint a finally a canvas cover for the bed hoops.
new ape by Ben Modified, on Flickr" />
Here is a video of the Maiden Voyage. It went well with the exception of a leaky camera suction mount!
I really need to learn to use a bead roller.
Cool project, as always.
CLynn85 said:I really need to learn to use a bead roller.
Cool project, as always.
Thanks!
Cool.....there was a real APE running around the VW show today .......original rat look.....
This is a very cool project, and seems much more interesting than the cushmans I have driven.
Very cool. Is that street legal where you are? I've been looking for something to run to the airport three miles away, and I have this KZ 650 hanging around .....
Chesterfield said:This is a very cool project, and seems much more interesting than the cushmans I have driven.
Thanks! Moving the engine from under the seat made a world of difference also!
914Driver said:Very cool. Is that street legal where you are? I've been looking for something to run to the airport three miles away, and I have this KZ 650 hanging around .....
Yes, street legal. As an added bonus, there is an exemption to the helmet law for an enclosed motorcycle!
In reply to Ben_Modified :
Your creative genius and considerable fabrication skills never cease to amaze me. Keep up the good work and please keep posting.
Cool build! Brings back some memories.
When I was 7 back in 1989, I visited Italy with my dad. He's from there, and we went to his hometown in the mountains of Calabria. We spent a lot of time hanging out in the town square, which is more or less a "bowl" between the big hill coming into the town and another big hill where most of the houses were. Every single day, we would see guys coming into town on those Piaggio 3-wheelers from the big hill. They would always cut the ignition and see how far they could coast, and it was hilarious to watch. Every time one of them did it, everyone would stop to see how far they would make it. One guy almost made it up the 2nd big hill where the houses were and everyone was cheering him on! 
Ovid_and_Flem said:In reply to Ben_Modified :
Your creative genius and considerable fabrication skills never cease to amaze me. Keep up the good work and please keep posting.
Thanks so much!
Tony Sestito said:Cool build! Brings back some memories.
When I was 7 back in 1989, I visited Italy with my dad. He's from there, and we went to his hometown in the mountains of Calabria. We spent a lot of time hanging out in the town square, which is more or less a "bowl" between the big hill coming into the town and another big hill where most of the houses were. Every single day, we would see guys coming into town on those Piaggio 3-wheelers from the big hill. They would always cut the ignition and see how far they could coast, and it was hilarious to watch. Every time one of them did it, everyone would stop to see how far they would make it. One guy almost made it up the 2nd big hill where the houses were and everyone was cheering him on!
That sounds like fun!
This is amazing. I've been waiting for this one since you mentioned you picked a cushman up a while ago. Your vision of what could be created out of that pile of parts in the first pic blows me away. Bravo!
Dead_Sled said:This is amazing. I've been waiting for this one since you mentioned you picked a cushman up a while ago. Your vision of what could be created out of that pile of parts in the first pic blows me away. Bravo!
Thanks! I appreciate the encouragement.
The stuff you come up with is amazing. That thing is awesome!
Doc Brown said:The stuff you come up with is amazing. That thing is awesome!
Thanks! Got some work done on a set of handlebars today and cleaned out the carb. It is coming along quickly!
handlebars by Ben Modified, on Flickr" />
Finished these today
ape bars by Ben Modified, on Flickr" />
I was just curious about your opinion on how much the numerous changes to the cushman has affected the handling compared to stock?
Chesterfield said:I was just curious about your opinion on how much the numerous changes to the cushman has affected the handling compared to stock?
I would think that it handles much better. Moving the engine from under the seat to behind the rear axle has got to have made it much more stable. Also the rear track is wider. I have taken some tight corners at a good speed with no indication that it would tip, though with the diff locking feature, it could be driven on two wheels.....nah. Note to self, I am too old to be young and stupid.
So it only has one forward gear to get it from 0-50? Interesting build!
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