Author Topic: 46cc Poulan Carb Mount Mod  (Read 601 times)

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Offline Chris-PA

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46cc Poulan Carb Mount Mod
« on: September 04, 2015, 04:29:19 pm »
I have sort of a love/hate thing with my 2775 (Type 1):  It has a lot of appealing characteristics, as it is light, narrow and easy to handle, and it's got great power for a simple 46cc clam (it pulls a 20" just fine) - especially ported.  This was the first saw I ported, and I enjoy using it - when it works. 

Personally I think they needed to increase the mass of the counterweights when they increased the displacement from 40cc, and it's constantly trying to shake itself to pieces.  The A/V works great so you don't feel it, but the engine bolts and muffler bolts are always trying to leave, and the Type 1 muffler heat shield will fatigue fail and melt your chain brake handle.  That's exacerbated by failing to use any sort of locking hardware at all.  And then the A/V system is weak, especially the rear spring that's at right angles to the bar and screws into plastic.  But by now I've redesigned and fixed most of that, which leaves just one more problem area - the carb mount. 

There are three problems with this design.  First, the diameter of the steel plate is only 0.575, while the carb outlet is about 0.625", so it leaves a restrictive lip all the way around.  Second, the steel plate has those nice slots cut into it, but they are totally useless as the rubber boot already has a channel formed into it.  There's very little sealing surface and no room to enlarge the center hole.  Last, the rubber boot deforms and further blocks the inlet, sometimes opening a passage between the impulse and intake. 


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Offline Chris-PA

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Re: 46cc Poulan Carb Mount Mod
« Reply #1 on: September 04, 2015, 04:42:13 pm »
The first thing I tried was to draw and 3D print a new mount without the slots and with a sleeve that would hold the boot open.  I was not happy with that as the strings did not seal well.  Next I cut a new plate out of aluminum (about 0.075" thick).  I made the center hole 0.625" with a step drill bit.  That got rid of the slots, but still gave no way to hold the boot open, so I looked for some sort of tube that was about 0.625" OD and would fit into the boot, but thin wall so the ID didn't block the intake. 

Eventually I found the can of a common electrolytic capacitor (we use lots of these at work).  It's soft and thin and cutting a tube out of it was quite difficult (I found the sanding drum from a dremel could be put inside and used to grind the top of the can off).  But it fit perfectly and I was able to press it into the center hole - with just a bit of JBQwik it should stay in place (I was worried about it getting swallowed by intake port). 

The orange tubes were cut off the end of some vacuum caps and make it easier to assemble. 

Offline Chris-PA

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Re: 46cc Poulan Carb Mount Mod
« Reply #2 on: September 04, 2015, 04:46:52 pm »
Last, I bought a couple of the carb isolator/supports used on the later Type 3 & 4 saws.  I have no idea where they are supposed to go, but the whole carb arrangement on this saw clearly needs some support at the front edge, so I wedged it under the bottom of the air filter mount.  My Husky 142 has a bracket on the front of the carb.  Previously when I would run the saw without the top cover on the whole carb would vibrate all around.  The top cover helps to support it but after a while it wears a groove in the rubber partition seal (if you epoxy it on that is, otherwise they just fall off). 

Offline Cut4fun .

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Re: 46cc Poulan Carb Mount Mod
« Reply #3 on: September 04, 2015, 06:07:51 pm »
 Holy cow Nice thread. 

One of those saws I only get in from time to time. 4620 295 2900 etc.  Only have the farmhand 295 I took on trade also.
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Offline Chris-PA

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Re: 46cc Poulan Carb Mount Mod
« Reply #4 on: September 04, 2015, 08:01:37 pm »
Holy cow Nice thread. 

One of those saws I only get in from time to time. 4620 295 2900 etc.  Only have the farmhand 295 I took on trade also.
It's not a saw I can recommend to people due the the various design mistakes, although I have not played with any of the later ones - maybe some of that got fixed.  If you know what to expect they are really nice to use though and they really go with just some minor work. 

The A/V versions of the 42cc family (PP260, etc.) are a lot sturdier and smoother, but they are considerably wider. 

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Re: 46cc Poulan Carb Mount Mod
« Reply #5 on: September 05, 2015, 12:36:10 am »
Pretty cool stuff there.   That is what I call re-purposing items.   I have never worked on one of those saws before so some of the flaws you mention I have not seen.   I mainly have the Poulan 295 and 260, which to my knowledge are not bad except for the screws that go through the bottom that hold the engine in place.   I have seen those come loose. 
PP 505, 475, 445.

Offline aclarke

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Re: 46cc Poulan Carb Mount Mod
« Reply #6 on: September 05, 2015, 07:31:58 am »
Very cool! Nice job.
I'll take a couple of AR15 lowers while you have that 3d printer fired up!!  Lol

Offline Chris-PA

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Re: 46cc Poulan Carb Mount Mod
« Reply #7 on: September 05, 2015, 09:12:19 am »
Pretty cool stuff there.   That is what I call re-purposing items.   I have never worked on one of those saws before so some of the flaws you mention I have not seen.   I mainly have the Poulan 295 and 260, which to my knowledge are not bad except for the screws that go through the bottom that hold the engine in place.   I have seen those come loose. 
Thanks!  When I'm making something and need material for a part I tend to just stop and look around for something made of the right size & material stuff.  Usually something will turn up.  The world is full of parts that just need to be liberated from whatever they're in now. 

Your 295 is basically the same saw with the same intake, but the muffler will likely be different. 

Those engine bolts come loose because the cinch up against a shoulder bushing that is free to spin in the case (so no lock washer would help anyway), and with the vibrations they back out.  Mind did that, causing considerable damage (oil pump, etc.).  I replaced he factory tri-lobe thread forming screws with M5 cap head screws as the thread area is fully round, and Loctited them in. 

The PP260 is a different (and better in my opinion) design.  They're tough as nails and just go, but they make less power in stock form.  With a compression increase and some porting they run very well though. 

Offline Chris-PA

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Re: 46cc Poulan Carb Mount Mod
« Reply #8 on: September 05, 2015, 09:18:57 am »
Very cool! Nice job.
I'll take a couple of AR15 lowers while you have that 3d printer fired up!!  Lol

The 3D printed part didn't work in the this case - it's neat but has a LOT of limitations.  I did make some case stuffers for my PP260 which are holding up well so far (the first try failed).

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Re: 46cc Poulan Carb Mount Mod
« Reply #9 on: September 05, 2015, 01:31:03 pm »


The PP260 is a different (and better in my opinion) design.  They're tough as nails and just go, but they make less power in stock form.  With a compression increase and some porting they run very well though. 

I found the poulan pro 260 and PP 220 bullet proof saws. JMO
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