Cracks, rust and damage are not the end of the line for a cutting deck. In most cases, they can be rebuilt, repainted, reinforced and put back into service, saving a significant cost over new replacement.

A rebuild starts with full disassembly and cleaning/stripping areas that are rusted, cracked or damaged for inspection.

Worn and damaged sections are cut out, leaving clean, sold material for new sections to be fabricated and welded.

New, thicker steel is shaped, cut and welded into place.

Chute braces are often fabricated from new, using solid steel rod.

Extra bracing can be added in sections that are prone to distortion and warping.

Cracks that form around brackets are welded.

The deck is then cleaned, prepped and painted. Worn or damaged bearings, spindles and blades are replaced as part of the assembly process, then the deck is ready to fit into the mower for use.

Other repairs include reattachment of broken brackets, with thicker sections to prevent further cracking.

Spindle flanges which have been damaged or thrashed out can also be fixed, with reinforcement plates added to stabilize the section.

Modifications are also possible, to enhance cutting perfromance in long grass and reduce dust blowout and clogging.

Above is a rake section added to pull grass from the edge of the deck closer to the blades, ensuring a full width cut, especially in longer grass.

Front section lift and brace, which exposes the blades more directly to long grass and ensures full, clean cutting. Mulch and exit baffles can be added to encourage finer cutting and better clearing.