Chainsaw Repair

Well I had a bit of luck, or something like that.  24 hrs with the niece, followed by a 6hr overtime shift to grab some extra bucks, and home by 930 tonight.  Wife was beat, so I got some time for me!!  Got the saw assembled, most of the way, at least enough for the liquid gasket to have 3-4 days to set, so I'm happy.

Cylinder in place!!



New intake is so much more solid, doesn't budget at all!  I see why this was such a big deal, can't believe this was factory now that I've seen it!!


Man it went together so much better with the new intake clamp.  I really am amazed at how much play there was before as compared to now when putting the carb and air filter support back in place!


Now the dilemma.  I test fit the 288 deflector on the muffler to look at possible options for exhaust. (No offense to your effort KRL, just trying to figure how to finish it up)  With the placement of the muffler bolts, I am left with the option of directing the exhaust at the bar or up and left (11 o'clock position) from drivers position, if you will.  Think that will be a PITA or not so much?  I think the up and left direction would probably be OK, but I do think I could get the 288 deflector onto the clutch side of the muffler also, then aim it straight forward.  Only problem then is that there is the insert for the muffler bolt running through the exhaust path.  Decisions..........

Oh, and as an aside, I broke in the new torque wrench and made sure to torque to cylinder bolts to 10n/m.  Never had a use till now to use it but just thought I'd throw that in.  I would have surely over-torqued them had I not used it.  I have always been the type to get on 'em till they were tight type, but I am glad I went this route this time.  Once again, thanks for the advice. 

Now the dilemma. I test fit the 288 deflector on the muffler to look at possible options for exhaust. (No offense to your effort KRL, just trying to figure how to finish it up) With the placement of the muffler bolts, I am left with the option of directing the exhaust at the bar or up and left (11 o'clock position) from drivers position, if you will. Think that will be a PITA or not so much? I think the up and left direction would probably be OK, but I do think I could get the 288 deflector onto the clutch side of the muffler also, then aim it straight forward. Only problem then is that there is the insert for the muffler bolt running through the exhaust path. Decisions..........

 I am with ya, 11 o'clock would work but you would be getting the exhaust in your face and you would end up with chips getting in the muffler and possibly being ingested by the saw, not good, down and towards the bar probably not good either, side or top may be the only options left however top usually melts the top cover if not way to the front of the muffler. Perhaps look at another form factor for the outlet, like a tube of some sort maybe a piece of oval tubing from a metal bicycle frame or a 60° copper plumbing elbow.

JohnG another guy on here AlSled does a really nice job of enlarging the factory port and welding on a larger deflector. I asked that he post a picture in this thread so you can have a look.

I have had the same problem with the screws. I either pop rivet them or, I have trying using a long tapered punch, drill a very small hole where the screw goes, then use the punch to form the thin metal into a funnel shape a little smaller than the screws I am using. IMHO the taper in the hole gives the screws more purchase. I have one together like that and so far it is holding, not a 350 but a 372 but should not make a difference.