SCOTT, TODD - I think Kraig has some pic's of the changes I made to my 38" deck. It never trimmed close enough to suit Me on the left side so I used a saber saw to cut off about an inch of steel and wrapped the ends around leaving about 1/8" clearance to the blade. The discharge chute always plugged in heavy and/or damp grass so I increased the width of it as far as I could. Plus I replaced the baffles under the deck with 2" tall versions instead of the stock 1-1/2", plus I put a horizontal lip an inch wide just behind the forward edge of the deck, it holds the grass down and allows clippings to exit the deck better. And I put a set of the spherical gauge wheels on the front like Kendell's deck has on in the picture of Him "Pulling His Calf". I also blueprinted the deck like the write-up Steve B. has in the FAQ's, everything is flat, bearings are tight, I have the front tips of the blades about 1/16"-1/8" lower than the rear. I have to be careful to keep the blades straight, sharpen them frequently, make sure the grass is dry when I mow, and watch rear tire pressure, a pound or two difference between the rear tires effects how it mows side-to-side.
I'm still not real happy with the way the little short blades on the ends mow, they're too short in My opinion, the 38" decks have different pulley ratios and they spin so fast they actually pull harder than a bigger deck. Now that I have more HP in the 72 I mow with most of the time I'd like to modify a 42" deck the same way I've done the 38" deck. I think the bigger outside blades would lift the grass run down by the front wheels better. Plus I have a couple places in the yard where I can't fit My 50" deck on the 982 into because of trees, and a 42" or 44" deck is all the wider I can run in those places. I only mow in first gear with the 72 because it has the fast 19T 2nd gear and that extra 4" per pass would reduce My mowing time about 10%. My 38" deck doesn't mow as nice as a Simplicity deck but it's real close. Definitely better than the 50" deck on the 982. Plan is to get the 70 refurbished, turn it into a 100 with the old K241 out of the 72 and run the modified 38" deck on it. The 70 has the slow 16T 2nd gear and that's a much better mowing gear than the 19T. I do have the 38" deck from the 70, it's the later model with the steel ends, not the CI deck, I may try to convert it into a modified 42" deck like the 38" for use on the 72. Lord knows I have enough scrap steel sitting around and enough welders.
Those old mower decks were made from heavy enough steel You can arc weld them easily. I didn't have My MIG welder when I made the changes, just the AC Buzz Box and I used 3/32" 7014 rod to do all the welding. But I REALLY need another mower deck around. No room now to walk around the shop without walking from the tires & footrests from one Cub to the next.