Thought I’d share my progress in this, so far I am just a few days into the restore. The front right corner of the hilo was caved in where the pulley pulls the cable. This was due to rotten plywood, so step one was to replace that. I added a much stronger piece of aluminum angle stock to clean up the whole front base and add some additional rigidity to the system. Worked great and really is much stronger.

Next step is in the interior I have a few pulleys that are lifting off the mounts and I need to get them back to a stable position. Any tips are welcome, my current plan is to take em apart and put them back together with additional brackets for support. Will post pics of that soon. Current pics are before after the first repair. We bought it with this paint job, it is soon to change!

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You have the right idea with your repairs. Make the repairs better than factory. Several of our forum members own HiLos of this vintage and have restored them. We are here if you have any questions.

Thanks Sam, that’s my plan, made some big structural improvements to the interior pulleys today. Looks like most of the bottom top interior wood is rotten out so next is to replace the back and sides of that. Any tips on doing that without removing it the top?

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