Poulan Pro 505 Clutch Cover Repair

[JMoney]

I have been unable to find a replacement clutch cover for this saw, so I am going to try and repair it. It doesn't have to look good. Here is the damage:

So what I would like to do is JB weld all of the pieces back together. Then fabricate a metal piece (probably aluminum since I don't have a lot of experience or tools for metal working) to serve as a brace, from where the cover bolts on all the way to the back (covering the label area), and JB weld this in place as well. I originally thought it was just in two pieces, but after removing it from the saw, it is in much worse shape.

I don't use this saw much, maybe once or twice a year, but I currently need it and I can't really replace the whole saw right now. Any thoughts or better ideas?

 

[Maintenance Chief]

Grab a Jonsered 2077 or 2083 clutch cover off EBay, same saw.
No amount of jb weld is gonna make that hold in those locations.
Hell you might even be able to butcher a 372 husqvarna clutch cover to fit? I know the 395 has wider bolt spacing, because I used a bar plate in my poulan 475 to help protect my clutch cover.

 

[JMoney]

I would grab a 2077 or 2083 if I could find one. Maybe the 372 can be made to work. When I first came up with the plan I didn't realize one of the bolt holes was blown out, but I really don't know what else to do.

 

[Maintenance Chief]

Ive got a couple of spare blue ones for a 372, I get one out to measure the bolt spacing.
If it'll bolt up I'll send one to you .

 

[Maintenance Chief]

Ok so the bad part is the Poulan/Jonsered is a little bit more narrow than the husqvarna? As you can see the bar plate from the poulan's saw laying on the 372 style clutch cover.
Personally I think you could slot the rear hole and bolt it down, probably have to trim the top and rear slightly also? But definitely not out of the realm of possibility. Plus you could gain a clutch cover side tensioner!
Pm me your adress and I'll send you a cover if your interested.

 

[Maintenance Chief]

 

[ManiacalMark]

^want

 

[Filthyphil]

Good luck finding clutch cover. Ive been looking. One came up for sale the other day nos it sold immediately i was kicking myself i didnt see it first.