044/046 Hybrid Build

[earlthegoat2]

After the cylinder is taken care of there is some work involving the muffler. Nothing complicated here. Some spacers or washers have to be utilized to get the muffler snug with the case on the bottom two bolts as you secure the muffler cover on. I'm still trying to source some spacers to my liking but have since used a few washers. The PTO side is quite difficult to put a loose spacer or washers into so it would be ideal if a spacer could be welded to the backside of the muffler holes then there would be ease of install and less parts to worry about.

Muffler installed with after market dual port cover. Last photos of the saw with carb and air box installed. I ran into trouble installing the top cover. It may have something to do with the top cover being non decomp and the cylinder having a decomp. I installed a decomp plug in the cylinder so that is not being utilized. In the end I had to trim som material off the front to clear the brake handle?? and that seemed to solve it.

 

[earlthegoat2]

Cover wouldn't fit until after removing a bit of material off the front and then it bolted right up.

Here it is in action with a 25" bar and ripping chain as I am free hand cutting the sides of a log I am milling.

I did forget to put the heat deflector under the muffler and I guess that caused the oiler worm gear to melt and bind up the oiler. Need a new oiler and worm drive. I have since put the heat shield on that came with the gasket kit.

 

[Wonkydonkey]

what have you done with the exhaust, iirc. you need a spacer at the bottom, like a washer. but they need to be joined as ones fingers cant put it in the right place..on one s

edit: I was typing while you posted

 

[BuckthornBonnie]

I have since found a bit. There is a pretty good one on here from last year but its not detailed enough for someone who has never done one before. Canadian Farm Boy was the main contributor to the build. Dalls 044 Hybrid was the title.

Basically, when I became interested in this build I was attempting to search for "putting an 046 cylinder on an 044" and got very little. This was in January of 2016. If I would have typed "044 hybrid" or "046 hybrid" I would have found more info. Didn't really know they were called that until more recently. Not new to chainsaw repair but definitely new to chainsaw hot rodding.

AdirondackStihl, Basher, others have done a few, too.

Re: spacer—good ones have been designed by members here and on AS. DDave had them listed at one point I think.
Good on you for doing a build thread, though.

 

[MustangMike]

I'm surprised you melted the oiler. Did you open the muffler up to let it breath a bit better?

The older saws with more opened up mufflers did not even have heat deflectors.

 

[earlthegoat2]

I opened the original opening and then put on a dual port cover. It's pretty open. I tuned it by ear pretty rich and then verified with my tach and it was running 13k. Maybe the oiler gave out but there was melted plastic from the worm gear inside the oiler cogs which is what jammed it up.