Stihl ms 460/660 Hybrid. 469e

[NateSaw]

Nope.... 93, or maybe 110 LL... heres hanson ported 23cc that supposedly put out 4.3hp on a dyno before i got it... shes small but shes strong.... i upgraded from that one to an RCMK motor, 25cc pushing 5.2hp...on pump gas...

We need to build a saw around that

 

[bogieboy]

We need to build a saw around that

i wonder how similar the motor is to the cheap zenoah clone top handles, if the port timing could be applied to those cylinders....

 

[NateSaw]

Alrighty then... At the beginning of this thread I believe I referred to a chapter 1, being the piston. I also believe I forgot to labe a second chapter, which would've been the intake riser, choosing the 660 boot, deciding to run with the HD 16a carb, choke linkage etc... That'd be chapter 2. Chapter 3, and a long one on my side of things has been the cutoff for me feeling thus far, efforts have been worth it. I wouldn't say this chapter has no worth, but I would definitely say that time sunk into this part of the saw, only has the benefit of teaching me how arduous mold making can be. So here it is, chapter 3. Making a mold of my modified air filter cover....
Even Rai Rai was looking at me like "What in the actual fugg are you doing now?"
Old hot rodders trick, stretch some panty hose, hit with glass resin. Skim with filler, you know the deal.

 

[NateSaw]

I found out in this chapter my dyslexia is dyslexic. My wife said to me, "You're trying to turn your brain inside out!". I was indeed. And back, and forth, and so on. The challenge in my mind was a dimensional one. Dimensia? Idk. The plastic these things are made of is roughly 0.060" thick. I ordered petg sheet at the same thickness. The end goal is to be able to vacuum form covers, as to not pucker everytime someone else's dogs dig into this thing in the saw box on the bucket truck. I wanted to have a care free attitude about the plastics on this saw so it could do work and prove whether or not the guts would hold up....
So. How do I make a mold, then a buck, that carries the exact inside dimensions, so that I can pull a form over the outside, and it looks like it fits... We'll, I'd have to cast the inside then.

 

[NateSaw]

First I had to give it a proper hole for the thumb screw. Probably the only redeeming quality on the stack of max flow covers on my shelf. Good donor.
Then I had to make the oustide stronger.
Then I had to make the inside smooth.
Filling and sanding went on for days. I mean DAYS!

 

[NateSaw]

Now I had to frame it. And fill that. And make that one with the cover. And fill the edges. And sand. And fill. And sand....

 

[NateSaw]

Then I had to build up with primer. And sand. And prime. And sand.

 

[NateSaw]

I was convinced first pour would destroy the mold. It was hard as frig to get out. Car wax doesn't get it. But.. The mold survived. So, not a complete failure. I know what to do now. This weekend, I'm pulling a good buck out of this thing, it's getting a skim coat of SOMETHING strong that can be polished, and a sheet of petg WILL get pulled over it on the vacuum table. I'll take a video. Success or failure will be posted here by Sunday
WUT DA FAAAACK!!

 

[NateSaw]

I'm always put of order
Before I did anything with the cover, I had to make a filter base. It's important, as it ties the tank assembly together with the carb. And having lengthened that tract, it's more critical for strength.
I procured a pair of farmertec bases, cut one to clear the carb and linkage etc... Cut one to support the filter.

 

[NateSaw]

Then came the panty hose. Locked in with resin.

 

[Ketchup]

This is downright inspirational. Both interesting and impressive.

 

[NateSaw]

This is downright inspirational. Both interesting and impressive.

Thanks Caleb. If not comical

 

[Mastermind]

Thanks Caleb. If not comical

Very cool.

 

[Powerstroke Cowboy]

Very nice work! You have more patience than I do!

 

[drf256]

Amazing work Nate. Keep it coming.

 

[NateSaw]

Thanks feller. I gotta say. I didn't get a chance to know him... But the whole way through this I kept thinking Steve the boat guy would've had some advice on how to do this mold and glass work.

 

[NateSaw]

Fellers *

 

[NateSaw]

With some zip ties as pulling handles, and the use of petroleum jelly, this one came out usable. But it put up a fight. I need a better mold release. This one goes on the shelf to dry. I'll see if tommorow'S has less bubbles, and pulls more intact.

 

[NateSaw]

That went way better than expected.

 

[Ketchup]

That’s cool. I think I have that same shop vac. How are you heating the polymer sheet?

Also, what are you using as a release agent? We want the details!

Really enjoying chapter 3 (4?).