Stihl 046 build…a little bit Frankenstein

[ManiacalMark]

So I bought this nice used 046 over a year ago and collected many new parts for it. Don’t burn me at the stake this is my first build thread. I know it won’t be perfect because it was a lot more too my on in my head to stop and take pictures (which I’m sure there isn’t enough of) and that messed up my pragmatism slightly.

 

[ManiacalMark]

So it seems I forgot a couple at the beginning. Bottom end was torn apart, rebuilt with all new OEM seals, bearings gaskets. The piston is out of an ms650 which is much taller than an 046 piston. A 372 BB piston was option #2 but that would have to run top ring only. Base left as is cleaned with fine scotchbrite chamber cut until it just barely touched with no gasket then cleaned with the sanding mandrel leaving me at .0195” squish, which is good to me.

 

[ManiacalMark]

Also the case was left as is and coated with diamond coating.

 

[ManiacalMark]

So then I timed the cylinder with said piston, ended up at
Ex-107
Transfer-125
Intake- 67
Time for some grinding

 

[ManiacalMark]

Also, the pin bosses of the ms650 piston need to be relieved quite a bit for the bearing and rod end to fit in there comfortably.

 

[ManiacalMark]

Bigger piston for a bigger saw with a bigger crank/ rotating assembly. So my goal was to get the weight even or under. 1st pic is 046 with rings, 2nd is 650 with rings after relieving bosses, 3rd is after opening up the windows. Perfect!

 

[ManiacalMark]

Brand new HO oil pump installed
Flywheel key taken down .022”
Two halves of the saw reuniting

 

[ManiacalMark]

Muffler modded, baffle left barely in there for some strength, side outlet I made from 16 gauge and gas welded it on. Muffler heated up and coated with rustoleum ceramic 2000* paint.

 

[ManiacalMark]

Final product, new older style wrap handle, new clutch cover diamond coated, original starter, tank and plastics.

 

[ManiacalMark]

Final numbers are
Ex-101
Transfer- 117/118
Intake- 72

Probably going to need more intake but I’ll run it and see how I like it thus far.

 

[ManiacalMark]

I’ll also probably add a 3rd port to it similar to this one on my 10mm 044, or rob this one for the 046 for now lol.
And yes the screen isn’t welded in I hand made a plate on the inside to slide the screen in and hold it down, factory like.

 

[ManiacalMark]

Added my 3rd port and tweaked the tune before I get a cutting video

 

[ManiacalMark]

Backed her down to a bit more fat of a tune, no more 4 stroke at that rpm

 

[Maintenance Chief]

Nice! , I'm kinda obsessed with my 046 and 460 right now.
I ended up going with a Dukes pop up in my 460 and was able to use the oem piston for the 046. I didn't go crazy with the builds,but they both feel very snappy! and cut very strong.
How much do you think came out of the chamber for the 650 piston to set right?

 

[ManiacalMark]

Probably 0.040”, if I’m not happy with how it runs like this I’m pulling the base gasket and re working the whole cylinder.

 

[Maintenance Chief]

I wonder how it would run just raising the stock cylinder, ports and all bumped up .040?

 

[Wood Doctor]

Here's my experience with a Stihl 046 Mag. I received it this way:

Then I rebuilt it and it ran beautifully:

A "friend" borrowed it and never returned it after I loaned it to him. Believe me, I will never forget this saw.

 

[ManiacalMark]

Doesn’t sound like much of a friend that’s for sure

 

[ManiacalMark]

Will have a cutting video tomorrow.

Ran it today in some big seasoned white oak, 28” bar, 72CL with the rakers @ 0.040” pulled good and hard until I split a nail down the middle.

 

[ManiacalMark]

Also I can’t say I’m like over the moon with the results hard to tell so far. Burns more fuel than I thought it would for 72* intake.