Brewz Saw Builds

[Brewz]

Hi Folks.

I have saw build threads all over the place and thought I would start a thread where I can keep all my saw builds central.

I'm not doing anything special like some of the members on here but I have fun learning to make saws go faster.

I guess I should start with some links to past build threads:

Stihl 076 Super that still isn't running but is close
http://opeforum.com/threads/stihl-076av-rebuild.2645/

Stihl 090
http://opeforum.com/threads/stihl-090-rebuild.2631/

Stihl 10mm 044
http://opeforum.com/threads/stihl-044-10mm-project.4548/

Husky 394
http://opeforum.com/threads/husky-394xp-rebuild.3826/

Husky 371
http://opeforum.com/threads/husky-372xp-tips-and-tricks-my-first-husky-rebuild.2225/

Stihl 066 (this saw ended up with a Husky 288 piston)
http://opeforum.com/threads/066-rebuild-port-job-etc.940/

 

[Brewz]

So I may as well start this off with my current build project.
Plastic badge 036 recovered from the rubbish dump.
Piston scored, cylinder has some transfer but will come up fine.
Clutch area was a mess. Looked like the clutch has come apart with all the nooks and crannies filled with oily sawdust mixed with chunks of metal.
All it had was the oil pump when I got it and this was busted too.

As it turned up here





Stripped and cleaned today



New bearings, crank seals and home made gasket



Put the wheel on it.
With no gasket it measured 105/119/80 with .018 squish.
Planning to take about .020 off the band and enough off the base to set squish at .018
Going to fill the intake
Hoping to end up with about 105/122/76



I have a new Meteor in the mail and will order the rest of the bits tonight.

 

[Mastermind]

Excellent thread Brews. I like the idea of keeping it together....

 

[Brewz]

So is upgrading the clutch drum just a case of running an 044 drum on an 036 clutch?

 

[Mastermind]

No sir, you also have to bend the oil pump drive up to contact the drum.

 

[skidooguy]

Thanks for gathering up all your links that could be very handy for somebody working on one of those saws in the future.

 

[Brewz]

Ok

Back to the 084 while I wait for 036 parts.

OEM cylinder measures 97/120/70
I am thinking if I take enough off the base to get the timing down to 100/124/73 with a gasket delete, and take the intake down to about 76, widen the exhaust and intake as needed, some flow and directional work in the transfers, dual port muffler mod and high flow filter, its going to be pulling 10hp+

@Iron.and.bark I have an "unobtanium" 1308 unlimited coil in the mail

Now.... to get the exhaust down this far, I am going to end up with a lot of compression in a 120+cc saw

I have an idea

Mill a slight dish in the piston top angling up from the intake to point the exhaust outflow towards the exhaust port.
This would lower compression to free up the saw, take load off the bearings and make it easier to start while allowing me to drop the cylinder a lot and keep the squish minimal for efficiency

Thoughts?

 

[Mastermind]

Thoughts?

Taper the edge of the squish band, where it meets the combustion chamber.

 

[Brewz]

Before I do that..... I dont have chicken wings and can drop start an 090 left handed

Will it go better with higher compression or less?

I have a 460 rescue D handle on order for it

 

[Brewz]

Cheap 084/088 Chinese piston turned into cutting mandril with a bit of power hacksaw blade tapped into a slot

Cuts the band nice

 

[Brewz]

Took the squish with no gasket from about .018 to .050 on the OEM 084 Cylinder
Will take about .040 off the base tomorrow so I can set squish using a thin gasket at about .022

Hoping to get the exhaust down to around 100*
With my 066 I got about 1 deg per .010 lowered so I am hoping to get 100/123/72 when done
Thinking I will take the intake down to end up with 100/123/74

Im really excited about this one

 

[Brewz]

Sanded the base of the 084 cylinder and got 100.5/125/71.5 with .019 squish.
Im not uncomfortable with that tight squish but would like to hear others opinions?
The next size gasket material I have will take me up to .025

 

[mdavlee]

Sanded the base of the 084 cylinder and got 100.5/125/71.5 with .019 squish.
Im not uncomfortable with that tight squish but would like to hear others opinions?
The next size gasket material I have will take me up to .025

That big of bore I'd go .025".

 

[Brewz]

Yeah your right
Will make a thicker gasket

 

[Keith Gandy]

Cheap 084/088 Chinese piston turned into cutting mandril with a bit of power hacksaw blade tapped into a slot

Cuts the band nice

View attachment 43505

View attachment 43506

How do u turn that piston once in the cylinder?

 

[jmssaws]

To me how tight you can get by on squish depends on how much compression it has.
020 at 175lb wouldn't bother me but 020 at 200lb in that big of a bore could eventually be a problem.
Also how much advance your running.

A 175lb 661 with a 017 squish and 040 off the key is a detonating monster but at 030 it's fine.

 

[Iron.and.bark]

That big of bore I'd go .025".

Motion seconded, especially if it's a milling saw.

 

[Brewz]

How do u turn that piston once in the cylinder?

I shape and bash a bit of timber in the piston and put it in the vice.

Sit cylinder over it and use both hands to rotate the cylinder keeping even pressure in the cutter

 

[Brewz]

Thicker gasket made, it now sits at .024
Just ported the cylinder and will start getting it together soon

 

[Brewz]

Final numbers on the 084

99/124/74

That'll do donkey!

When converting a saw with a dual key flywheel from limited coil to unlimited coil, which key way do I use?