Cushman brake/clutch lining replacement?

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Cushman brake/clutch lining replacement?

Post by Steve Webb » Wed Oct 30, 2019 6:14 pm

I have a 1946 Series 50 with same engine as the 53 airborne. I am replacing the linings and am up to the point of the rivet installation. Anyone done that and have tips for me. Parts from Dennis Carpenter and no extra rivets with the kit. Thanks
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Re: Cushman brake/clutch lining replacement?

Post by chibobber » Wed Oct 30, 2019 11:29 pm

Check out Hanson Rivets.They have all you need,Tools,rivets etc.With the right tool,it is fairly easy. On your brake linings,be sure to taper the leading edge.This helps with better contact for the whole shoe.

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Re: Cushman brake/clutch lining replacement?

Post by W. Winget » Thu Oct 31, 2019 3:36 am

Someone posted about doing their GPW/MB brake Shoes last month, a search would show their excellent visual "how to".
If in doubt about your riveting capability, you could opt to apply a layer of glue (the proper epoxy) on 1st, then apply the rivets, then your assured no movement and a permanent fixing to the backing plate.
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Re: Cushman brake/clutch lining replacement?

Post by Alex Schmidt » Fri Nov 01, 2019 12:59 am

Nobody here seems to know that the linings are riveted to the drum, rather then to the shoes!
Are your linings pre-drilled with the holes and countersunk holes? I just use a drift of the right size, clamped in the vice, then hang the drum over it, and peen the rivet end with a small ball peen hammer. Also check the shoes for wear, they seem to wear more than the linings!! Had some shoes cast in the past, but think they are all gone now.

Grtz, Alex
1910 P&M R.F.C. mtrcycle
1939 White 704 S 5 ton
1940 Matchless G3
1940 Norton Big 4
1941 FordGP #16601
1943 G.E. 75mm Pack How.
1943 Welbike Parascooter
1944 Cushman Parascooter
1944 Cooper Parascooter prototype
1944 DKW RT 125 N.a.

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Re: Cushman brake/clutch lining replacement?

Post by Steve Webb » Fri Nov 01, 2019 3:17 am

I worked it out pretty good. The linings had to be drilled and countersunk and my concern was keeping the rivet tight through them and the drum. I made this little tool that did that and did not damage the lining.

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The end stayed right on the rivet and turning the couplings let me keep pressure on rivet from inside and not damage the lining. Setting the rivets after that was easy.
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Re: Cushman brake/clutch lining replacement?

Post by Steve Webb » Fri Nov 01, 2019 1:01 pm

Had to make different tool for clutch lining same principle just a shorter piece. Ground all thread down until it only rested on rivet head and held it with pliers and turned coupler until tight. With high demand for this specialty work I will ramp up production facilities :wink:

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Re: Cushman brake/clutch lining replacement?

Post by tractor12 » Fri Nov 01, 2019 1:02 pm

Brilliant I need to do my two package kars soon and didn’t think about doing it this way
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Re: Cushman brake/clutch lining replacement?

Post by Steve Webb » Fri Mar 27, 2020 3:58 am

Well it worked well. I have my scooter running and don't have body on it and road tested but it is on a stand I built and lining's are in place and everything staying put and doing what they are supposed to do. No issues with clutch or brakes.
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Re: Cushman brake/clutch lining replacement?

Post by Steve Webb » Sat Apr 25, 2020 2:35 pm

Got it on the road last Sunday first time it ran in 17 years. I probably have 20 miles on it now just goofing around. No problems with clutch or braking so it does work :D
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Re: Cushman brake/clutch lining replacement?

Post by Steve Webb » Sun Dec 04, 2022 6:53 pm

I estimate about 1,000 miles on scooter now. Picked up a long screw in rear tire probably debris from clean up after Hurricane Ian. The rear tires are a real pain to remove so am doing maintenance and the brake lining will be replaced. Glad I made this set up. Clutch lining seems pretty good.
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Re: Cushman brake/clutch lining replacement?

Post by Alex Schmidt » Mon Dec 05, 2022 12:13 am

Glad it worked out fine! I just got a friends Model 53 running, after a lengthy restoration, we had the linings glued/bonded in by a company, we'll see how it goes, first testrun in a couple of days. Will post some pictures later.

Grtz,

Lex
1910 P&M R.F.C. mtrcycle
1939 White 704 S 5 ton
1940 Matchless G3
1940 Norton Big 4
1941 FordGP #16601
1943 G.E. 75mm Pack How.
1943 Welbike Parascooter
1944 Cushman Parascooter
1944 Cooper Parascooter prototype
1944 DKW RT 125 N.a.


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