I have started building a DIY Cushman style scooter. It is going to use a Craftsman 42cc weedeater engine for power using a jackshaft to gear the little motor down. I will be posting pictures as I build it. Is anybody old enough to remember the cushman. There was one with a box like shell and the Eagle which looked more like a motorcycle style. I am going to make one with the box like shell over the motor.
Building a DIY Cushman Style Scooter
- Thread starter gstrope
- Start date
Yeah I remember them. I have helped get a couple running years ago.
Jim's Cushman Scooter Site Home Page
Jim's Cushman Scooter Site Home Page
Sorry man, I am not Jim. I am soooo sorry if I let you on to a wrong impression! 
I just left a link for those who are not familiar with what you are inspired to build.
I just left a link for those who are not familiar with what you are inspired to build.
When I was a kid, my uncle had a Cushman Eagle that wasn't running and was in rough shape. I've thought about getting one many times.
My brother and his friend had a pair when they were about 16 back in the mid 60's. They bought them at a yard sale as literal basket cases and my dad put them together and got 'em running again. One had bad wear on the crank from the seals, dad took it to the old time machine shop across the street from where he worked and the old guys there charged him $5 to weld and re-machine the crank.
Ok, made me get up and search through the DVDs to find the disk my other brother made of all the old family slides to get the picture. Dig the home made banana seats!
Ok, made me get up and search through the DVDs to find the disk my other brother made of all the old family slides to get the picture. Dig the home made banana seats!
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one of my old boss's had a Silver Eagle. had a foot clutch, went about 40mph...
i used it for lunch runs all the time.
i used it for lunch runs all the time.
My brother and his friend had a pair when they were about 16 back in the mid 60's. They bought them at a yard sale as literal basket cases and my dad put them together and got 'em running again. One had bad wear on the crank from the seals, dad took it to the old time machine shop across the street from where he worked and the old guys there charged him $5 to weld and re-machine the crank.
Ok, made me get up and search through the DVDs to find the disk my other brother made of all the old family slides to get the picture. Dig the home made banana seats!
Kevlarr, I think the bikes in the photo you posted are Mustangs....let me know if I am wrong. Those were bad a** bikes in their day, with a kick start single, a "real" transmission ect.
That's what I was thinking too. My uncle restored a couple of Mustangs about 15 years ago then sold them. They sound like a single cylinder Harley.
I wanted one sooo bad but they are just too small for me.
How about a three-wheeler? My brother Jim (Fossil on this forum) has this 1943 Cushman Military Police scooter, one of only eight built. All eight were prototypes, and the model was rejected by the War Dept (probably because it was so unstable). This is one of two still known to exist.
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Here is latest on the build. The first picture shows the frame now bent and welded. Here we are setting the angle of the head tube. The 2nd one shows the head tube in place and now we are seeing how much the fork needs to be extended. The 3rd shows the engine and jackshaft that I am going to use on the scooter. It is shown here on "the mule". My test bike that I use to try out new designs.
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And some more pictures. I completed the motor and running gear and needed a body. I decided to go with wood for soundproofing and light weight. I first sealed the body off so you coululdn't see inside at all. After testing the engine got too hot so I opened it up and put louvers on it. It runs better. After all this I am not happy with the engine. It is hard to start and has a hard time idling. I think I will rework it with a different engine.
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That's a pretty good replica of the old Cushman scooters. I had several as a kid (think we bought & sold them for around $10-25 dollars)
They had 5-8 HP side shaft engines with a centrifugal clutch similar to a go-cart . The kick starter was usually broken and we wedged clothes pins into the clutch to be able to push start them. Which was cool most of the time ....unless the pins DID NOT fly out of the clutch like we hoped they would. At that point you had no control of the power any longer
You had to shut it off or ride it wide open ..... Similar to Texas Downhill when snow skiing..LOL
I have plans somewhere for a scooter that resembles the old Cushmans with an enclosed body. Found them-- http://www.vintageprojects.com/mini-bike/Super-Scooter.pdf
We always called the Cushmans "Highlanders" though in most articles about them I seldom see any pictures of the basic scooters we rode. They were so simple they were disgusting... I've often thought of replicating one.
This might interest you.. www.nottacushman.com
They had 5-8 HP side shaft engines with a centrifugal clutch similar to a go-cart . The kick starter was usually broken and we wedged clothes pins into the clutch to be able to push start them. Which was cool most of the time ....unless the pins DID NOT fly out of the clutch like we hoped they would. At that point you had no control of the power any longer
You had to shut it off or ride it wide open ..... Similar to Texas Downhill when snow skiing..LOLI have plans somewhere for a scooter that resembles the old Cushmans with an enclosed body. Found them-- http://www.vintageprojects.com/mini-bike/Super-Scooter.pdf
We always called the Cushmans "Highlanders" though in most articles about them I seldom see any pictures of the basic scooters we rode. They were so simple they were disgusting... I've often thought of replicating one.
This might interest you.. www.nottacushman.com
Those two bikes are Mustangs. Great bikesMy brother and his friend had a pair when they were about 16 back in the mid 60's. They bought them at a yard sale as literal basket cases and my dad put them together and got 'em running again. One had bad wear on the crank from the seals, dad took it to the old time machine shop across the street from where he worked and the old guys there charged him $5 to weld and re-machine the crank.
Ok, made me get up and search through the DVDs to find the disk my other brother made of all the old family slides to get the picture. Dig the home made banana seats!
and i never knew you two were brothers! thats awesome!