G'day Mike
Take lots of photos of the mower from all angles.
Identify missing, broken, or seized parts.
Make a list of what you need to replace or repair (nuts, bolts, bearings, paint, blades, etc.).
Check for historical manuals or diagrams online
This gives you a clear idea of scope — saves frustration later.
2️⃣ Clean and Degrease
Even before sanding or dent repair, give it a good clean:
Remove loose dirt, grass, and grease.
Use degreaser on the reel, gearbox, and handles.
Avoid soaking bearings and shafts yet — just clean the surfaces.
Pro tip: Cleaning now helps you see rust, dents, and cracks better.
3️⃣ Disassembly
Take the mower apart carefully.
Label each part or use ziplock bags for small screws/bolts.
Take more photos during disassembly — very helpful when reassembling.
Order tip for novices:
Remove handles and frame panels
Remove cutting reel and bed knife
Remove gearbox, wheels, and axle assemblies
Don’t force stuck parts — penetrating oil can help.
4️⃣ Cosmetic Work (Rust & Dents)
Yes, generally cosmetic first:
Rust Removal:
Light surface rust: wire brush, steel wool, or sandpaper.
Heavier rust: naval jelly, vinegar soak, or a wire-wheel attachment.
Powder-coated or painted surfaces: consider stripping old paint first (chemical stripper or sandblasting).
Dent Repair:
Small dents: hammer + dolly or soft mallet.
Big dents: consider body filler if it’s on painted panels (not critical for mechanical function).
Final Prep:
Sand all surfaces to smooth metal.
Wipe down with solvent before painting.
5️⃣ Mechanical Inspection
Once the cosmetic surfaces are sorted:
Check the reel bearings, wheel bearings, and gearbox.
Spin the reel by hand — is it tight or binding?
Inspect blade tips and bed knife. They can often be sharpened rather than replaced.
Grease and oil moving parts.
Replace any missing fasteners.
Pro tip: This is easier after paint is cured to avoid scratching new surfaces.
6️⃣ Painting / Finishing
Mask off mechanical parts like bearings, gears, and blade edges.
Primer → Paint → Clear coat if desired.
Let paint cure fully before reassembly.
7️⃣ Reassembly
Follow photos and part labels.
Lubricate moving parts as you go.
Adjust reel-to-bed knife clearance (Scott Bonnar mowers are famous for needing careful adjustment).
Test-roll the mower before using it on grass.
8️⃣ Testing
Start with a small patch of grass.
Check for:
Smooth reel rotation
Proper cut height
No unusual vibrations or squeaks
Take your time.
Use YouTube or mower forums for visual guidance — there are Scott Bonnar enthusiasts with step-by-step videos.
Document everything — even small steps help during reassembly.
If something looks rusty but structurally sound, you can sometimes clean, prime, and paint rather than replace.
Cheers
Max.
