Repair exhaust mounting holes?

[Shibby]

Chainsaw took a hit to the muffler which ripped the mounting holes off and banged up the flange. Is it possible to pile up a weld and drill/tap new holes, or are the cylinders too delicate and warp or ruin them?

 

[huskihl]

Chainsaw took a hit to the muffler which ripped the mounting holes off and banged up the flange. Is it possible to pile up a weld and drill/tap new holes, or are the cylinders too delicate and warp or ruin them?

It’s possible. @srcarr52 and @Michpatriot do a great job

 

[Shane¹]

Got any pictures of the damages?

 

[drf256]

Very much doable. Issue is cost of repair vs cost of replacement jug if you can’t do yourself.

The exhaust flange, intake spout and the fins are far enough from the cylinder bore to allow repairs without warping the bore. The base is another story, I’ve warped bores doing those.

 

[Shibby]

Here's the damage. From a husky 394. I was thinking of cutting most of the debris and filling it back in. These cylinders seem to be near impossible to find so I'd like to fix this if possible.

 

[huskihl]

Here's the damage. From a husky 394. I was thinking of cutting most of the debris and filling it back in. These cylinders seem to be near impossible to find so I'd like to fix this if possible.

That’s a dandy lol Looks plenty fixable though

 

[Nate.]

Who really needs a muffler…… just gotta think of it as a strait pipe

 

[Nate.]

 

[Wilhelm]

That looks like a lot of carbon on what seems to be a section if remaining mating surface towards the muffler.
If so, that muffler was in a phase of destructing the cylinder for numerous tanks of fuel not just one hit.

If You value that cylinder and never successfully welded aluminum, send it to a verified Pro for fixing, without touching any of the damaged area.
Let the Pro do his/her own surface prepping.
Make certain that the cylinder doesn't have any other damage to ensure it is worth fixing!

Good luck!

 

[srcarr52]

That’s the most damaged exhaust flange I’ve seen. It still can be fixed.

 

[Shibby]

@Wilhelm this is a new to me saw, so you are most likely correct the saw was run for a while with the broken flange. Here's the muffler.

I have some friends who weld professionally so I may ask them to take a stab at it.

 

[Wilhelm]

@Wilhelm this is a new to me saw, so you are most likely correct the saw was run for a while with the broken flange. Here's the muffler.

I have some friends who weld professionally so I may ask them to take a stab at it.

Wow!
That's bad!

 

[Wood Doctor]

Wow!
That's bad!

Agreed. I just fixed an MS661c with ripped out muffler bolts using my own shop-made inserts, but nothing was as bad as what OP shows here. This is a first class disaster. I would replace the whole top end, but some guys here love a challenge.