HELP! 500i damaged case

[AJ Delhomme]

Today I went out to cut down a rotten tree around the pond. Well needless to say my saw got stuck. Broke the chain cover and also broke off the inside spike top bolt and case. It cracked off the case in the middle of the serial number. The case looks good other than that. Has anyone ran one with the top spike broken off? Or should I change case half?

 

[Duce]

Post a picture and see if Shane can fix it.

 

[jacob j.]

@srcarr52

 

[Colonel 428]

Yep, Shaun Carr is the guy you want to reach out to...

 

[Duce]

Post a picture and see if Shane can fix it.

Mr. Carr is who I was thinking of, he does fine work!

 

[AJ Delhomme]

Sorry taking so long to reply. Had to listen to some good preaching!!! I know the chain cover is toast but I’m just worried more about the case half. Will try to attach pics.

 

[AJ Delhomme]

More pics

 

[AJ Delhomme]

If I were to get the case half and change it, what tips or tricks I would need to know? I’m just starting to dig on here and internet for advice.
I usually work on my own stuff. Not scared to dive in head first. I know I can do it but things like the case bolt being replaced not reused…. Torque then 1/4 turn….. any other advice or help would be very helpful!!!

 

[davidwyby]

We need and @Onan18 500i thread

Maybe see some of his threads to get an idea about saw teardown and reassembly

It’s weldable

 

[Gary Courtney]

I found the 500i was very simple to re-build. After I got all parts in and started the rebuild I estimate from start to first run was approximately under 2 hours and I am just a neophyte.

 

[singinwoodwackr]

If I were to get the case half and change it, what tips or tricks I would need to know? I’m just starting to dig on here and internet for advice.
I usually work on my own stuff. Not scared to dive in head first. I know I can do it but things like the case bolt being replaced not reused…. Torque then 1/4 turn….. any other advice or help would be very helpful!!!

You need the Stihl case tool for the 500. A regular case splitter won’t work.
That, however, can be welded without disassembly, imo.
Pull the tank and all electrical components off…basically strip the saw down but leave the topend alone…and send it to Shaun.

The clutch cover? Just replace it. I’ve tried welding one…just too much impregnated oil.

 

[EFSM]

That, however, can be welded without disassembly, imo.

Without any alloy welding experience, I would second this.

 

[singinwoodwackr]

Without any alloy welding experience, I would second this.

Did one recently…stripped the electronics and welded the damage.
Put it all back together and the saw went back to work…tree service.
Lost argument with a tree…$250 in parts later… better than trashing an $1800 saw…which is what the owner had planned on doing

 

[AJ Delhomme]

Wow thanks for the encouragement!!!! I figured I would be tearing it completely apart. I will get clutch cover from local dealer and see if he knows someone local. If I can’t find any around here, I will hit up on here first a welder. Again thanks guys!!! I don’t feel so discouraged anymore.

 

[davidwyby]

Mag and alum transfer heat a lot, so any components that would be damaged by it need to be removed.

If no one else wants to do it or can, my shop can weld it.

 

[srcarr52]

Mag and alum transfer heat a lot, so any components that would be damaged by it need to be removed.

If no one else wants to do it or can, my shop can weld it.

I've welded many like this with only removing the chain brake parts that can be melted and the muffler for access. Everything else is far enough away to not be in danger.

 

[davidwyby]

excellent

Perhaps wrapping with damp rags too

Forgot that trick

 

[singinwoodwackr]

excellent

Perhaps wrapping with damp rags too

Forgot that trick

that's what we did on the one I had my neighbor weld. He's done a couple like that...works fine.