Stihl 090 rebuild

[Brewz]

Picked up a Stihl 090 today that has had a hard life.
It fell of the back of a truck, has a broken cover, broken AV mount, fracture in the fuel tank and leaks fuel, leaks oil, off switch is broken, spark plug boot is broken, AV mounts are stuffed, rear handle is broken where the top bar connects, tech screws holding the muffler on............ and that's what I found in the first 30 seconds.

But it has finger breaking compression, starts and runs first pull (couldn't believe it!), and has me as a new owner.

It came with a box full of spares that I will lay out and take photo's of over the weekend for you all to identify for me

Thus far I have $200 in it.

I am thinking a full strip, have the damage tig welded, sand blast it all and have it cerakoted in Stihl off white.

The cover has me worried.
Its very thin and I'm not sure if its reparable.
Does anyone know of a replacement sitting around gathering dust?

Also need the 090 part of the badge.

This thread will be dedicated to the rebuild with lots of photos to document it for future generations.

Pics of it as it stands now.

I am in love with it. Its almost as heavy as me and I cant wait to use it





Happy for peoples advice, opinions, recommendations, help and offers of parts to be posted up here.

Let the fun begin

 

[Simondo]

If it is going to be for you as a keeper then :A.. it can take as long as your patience and bank balance will stand ..OR : B ..If it to be done fore sale then you may consider doing what is needed "only" to make it into a saleable saw. Someone who buys it may be prepared to do part sorting and as long as the major mechanicals are "good" will give you a profit.

 

[CR888]

I wonder what the Chinese non critical parts like plastic covers, handles etc would be like? You could use OEM where it counts and add some China to make it look good. I need a top cover for my Contra & think I will go down the China road. If you were honest when selling it about what's what it should be OK.

 

[Chainsaw Jim]

You have some pretty heavy brass marbles to be showing Randy up like this.

Let the showdown begin!

All joking aside, you really scored on that one.

 

[Iron.and.bark]

Nice find think I have a few parts in a box. Will dig

 

[Brewz]

Hi Rogue, yours looks a lot newer than mine!
At this stage I am not rushing into the 090.
I am currently rebuilding an 034 super and an 076av, and once they are done, I may start looking at it in between other jobs.

I actually have 2 of the recoil starters.
There is a big box of bits that came with it.

iron and bark, I would love it if you could have a look for a rear handle.throttle trigger assembly and the base plate that bolts on under the fuel tank.

cheers

 

[Brewz]

Ok, so it is worth taking the time to fix up then.

 

[Brewz]

What is the top cover actually made out of?
I am wondering if it could be repaired?

 

[Iron.and.bark]

Think I have a top cover as well, can't check till next week though.

 

[Brewz]

Think I have a top cover as well, can't check till next week though.

Like, Like LIKE
Triple like!

 

[jacob j.]

What is the top cover actually made out of?
I am wondering if it could be repaired?

Usually those covers are made out of pot metal. I had an 08 cover welded once, and the welder told me "never bring me this *s-word again."

 

[Brewz]

Usually those covers are made out of pot metal. I had an 08 cover welded once, and the welder told me "never bring me this *s-word again."

Ha ha yeah it looks like it would be difficult.

Was wondering if it would be worth trying to cut out a neat section and tig weld in a bit of aluminum plate.

I will wait to see if iron bark has one taking up space first.

 

[Brewz]

If anyone has a saw like mine, would they be able to take a picture of the front AV mount for me?

The mount has broken off my saw and is currently held on with a very agricultural lump of metal and some bolts.

I will get a pic of it when I get home from work.
It may be repairable

 

[Brewz]

Pictures of the handle below.

Its really bad now that I look at it closer.

I am thinking I could cut off the top arch section, straiten up the front handle section and make a new arch top and weld it on.

Shouldn't be too hard.

 

[Brewz]

The bloke I got it from said it fell off his truck but I recon he ran over it with his truck and bent the handle in, which punched a hole in the tip cover and probably broke the original chain cover too.

 

[Brewz]

Here is the repair they have done to the front AV mount.

I am really interested to know how it looks when not broken so I can repair it.

 

[Brewz]

If I can rebuild the bar, repair the front AV mount, get a new rear handle/trigger assembly and a decent top cover, I may consider rebuilding it.

God knows what I will find inside.

How much are these old battle tanks worth if rebuilt and restored nicely?
Is it worth doing or should I just part it out.

I don't want to part it out though....... I want it to cut wood again!

 

[VinceGU05]

Hey brewz. Hope these pics help a little.
This is my monster. The later AV model.



And it's mount.







Just wondering. It looks like if you found a newer parts saw or parts the newer handle would bolt straight on.





Just floating some options for ya.

 

[Brewz]

*s-word hot mate!

I need to borrow your top and chain cover........ I will send them back, promise!

 

[Brewz]

My front AV mount is different.
Actually the case mount point is different.

It looks like the bracket off the AV mount has broken and someone has tried to weld it but failed, so the "farmer fix" was applied.

Its going to take some more research to work out how it is supposed to be mounted.