Seems the motor lugs are in bad condition. One broke off, and the other three are bad as well. We replaced them with new bolts and brazed the connections.

The cheapest I could find lugs was at our local TSC. They cost about 5 dollars for a pack two, and usually only carry two packs. Due to the lack of quantity and above normal prices, I just made my own. You'll need copper tubing, a tube cutter, a drill and maybe a vice and a grinder.

I started by cutting 1 3/4" sections of copper pipe. I then placed about half of the end into the vice as show in the picture below.



I then rounded off the corners with my grinder, then drilled a hole in the flat spot of the appropriate size.



I'm using 2g wire, and it fit rather snug into the newly made lug. I heated them up with a propane torch and soldered the lug into place. Then I placed a bit of heat shrink around the neck to help prevent shorts.

Sure looks different with out all the rust!

Not much has been done due to either lack of power (storms), and waiting on parts to come in the mail. Tires and rims did arrive, but only two of four. I contacted the place that I purchased the tires from and they said they would find out why I didn't receive all four. The two I got do look nice though! One can see a night and day difference in the picture below showing the new and the old.



Also been doing rust removal using electrolysis. Its very simple to do. Heres what you need.

Something to hold water
Metal rods to use as anodes (These rods will eventually be destroyed)
Laundry Soda (In a pinch you can use Baking soda, but its not as good)
Battery Charger (I've been setting my charger to 35 amps, but 6 or more will work)

Simply fill your container with water. Mix in 1 cup of Laundry Soda to every 5 gallons of water. Drop 1 or more metal rods into the container and connect to the "+" lead of the battery charger. The item you want to remove the rust needs to be submerged and connected to the "-" lead. Also make sure you do this in a vented area. I usually give the whole process 5 to 10 hours depending on how bad its rusted. However some things come clean in just a few hours. When the process is finished, there will be a black film over the item being cleaned, just brush it off with a soft wire brush. I usually coat whatever I de-rusted right away with either paint, or I rub it down with oil to prevent it from rusting.



For detailed information on how to remove rust by electrolysis Click Here

Spent some time this weekend doing some cleanup work. After a new motor bearing and some cleanup, we sanded all the rust off and painted the motor housing with Hi Temp Stove Paint. The differential and end caps of the motor are Cast Aluminum, so we painted those with Aluminum engine paint. Also shot the axle with the stove paint, and topped it off with some undercoating. The motor has tested good and sounds nice and smooth.