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dthieme

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Hey guys, another long post coming. I appreciate all the advice from everyone on my first post with the Echo CS-801p. I’ve decided to hold off on that saw for now while I’m waiting to hear back about a bigger carburetor. In the meantime, I’m hoping to learn more about porting by dabbling with some of my old saws.

I initially considered tackling the 371xp and 394xp’s that were gifted to me, but decided to hold off on those as well and start with one that has more personal value - a Stihl 056AV - my first “big saw”. The “Ole 56”, as I called her, was gifted to me after my dad retired her from firewood duty for being too unwieldy. Before then, I was mostly running a Stihl 261 that I got in 2010 as a junior in high school. I ran that heavy cinder block for 2 years during my winter breaks of college when my cousin and I would give our best attempt at logging. As fate would have it though, the saw fell victim to a bad ignition and ended up stuffed away in the back of my parents’ garage. Fast forward 10 years and I just bought my first house, and my first child is on the way. My parents have been cleaning out my “old junk” and the Ole 56 was one of the first items to be evicted. Besides the fact that I just picked it up from my parents’ this weekend, I wanted to start my porting journey with this saw simply because I have two additional parts saws to go with it.

My plan is to first try fixing the ignition and see if I can get it running. I did check the compression last night and for what it’s worth, it was around 152 psi. Through the bore scope, the cylinder looks to be in excellent shape. Not sure what condition the crank seals are in, but the bearings are buttery smooth. Assuming I can get it running, I’ll tear it back down and check the timing and squish on it. I don’t have any illusions of making it a regular use saw, but I also can’t stomach seeing it get junked so I figured it’s a good candidate for practice. The goal is a play saw for occasional firewood use that I might bring out for local vintage chainsaw competitions. If anyone has experience with this particular model or other Stihls of that vintage (045, 045S, etc.) I’d love to hear what you’ve done.

Also, beyond porting suggestions for this saw, does anyone have general suggestions for specific porting tools, learning resources, or other general two-stroke/maintenance tools for a hobbyist starting out? I was already recommended the angled handpiece from lucky dog so I’ll be looking into that. I’ve also seen a few nods to Scott Kunz videos on youtube so I’ll check him out. Are there any other measuring, marking, or machining tools that make life easier? How about leak-down testers, tachometers, seal drivers/pullers etc. As far as mandrels have you guys been machining your own? Is aluminum best or would nylon or a harder acetal plastic work? I don’t intend to make this a full-time job so I’m certainly not trying to go over the top spending money, but I would like to have the tools I need to succeed and enjoy the work. I have always been a saw fanatic and this is just another avenue for me to learn and grow in my obsession.

Lastly, on a side note, I did take a leap of faith recently and ordered a ported saw from a local guy I ran across on the forum by the name of @Stump Shot . I figured with never having run a modded saw, it would be best to start by running one built by someone who knows what they’re doing. Steve has been great to work with so far. He is excellent at communicating and seems to be very knowledgeable. Very excited to get that saw in my hands!
 

Stump Shot

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Hey guys, another long post coming. I appreciate all the advice from everyone on my first post with the Echo CS-801p. I’ve decided to hold off on that saw for now while I’m waiting to hear back about a bigger carburetor. In the meantime, I’m hoping to learn more about porting by dabbling with some of my old saws.

I initially considered tackling the 371xp and 394xp’s that were gifted to me, but decided to hold off on those as well and start with one that has more personal value - a Stihl 056AV - my first “big saw”. The “Ole 56”, as I called her, was gifted to me after my dad retired her from firewood duty for being too unwieldy. Before then, I was mostly running a Stihl 261 that I got in 2010 as a junior in high school. I ran that heavy cinder block for 2 years during my winter breaks of college when my cousin and I would give our best attempt at logging. As fate would have it though, the saw fell victim to a bad ignition and ended up stuffed away in the back of my parents’ garage. Fast forward 10 years and I just bought my first house, and my first child is on the way. My parents have been cleaning out my “old junk” and the Ole 56 was one of the first items to be evicted. Besides the fact that I just picked it up from my parents’ this weekend, I wanted to start my porting journey with this saw simply because I have two additional parts saws to go with it.

My plan is to first try fixing the ignition and see if I can get it running. I did check the compression last night and for what it’s worth, it was around 152 psi. Through the bore scope, the cylinder looks to be in excellent shape. Not sure what condition the crank seals are in, but the bearings are buttery smooth. Assuming I can get it running, I’ll tear it back down and check the timing and squish on it. I don’t have any illusions of making it a regular use saw, but I also can’t stomach seeing it get junked so I figured it’s a good candidate for practice. The goal is a play saw for occasional firewood use that I might bring out for local vintage chainsaw competitions. If anyone has experience with this particular model or other Stihls of that vintage (045, 045S, etc.) I’d love to hear what you’ve done.

Also, beyond porting suggestions for this saw, does anyone have general suggestions for specific porting tools, learning resources, or other general two-stroke/maintenance tools for a hobbyist starting out? I was already recommended the angled handpiece from lucky dog so I’ll be looking into that. I’ve also seen a few nods to Scott Kunz videos on youtube so I’ll check him out. Are there any other measuring, marking, or machining tools that make life easier? How about leak-down testers, tachometers, seal drivers/pullers etc. As far as mandrels have you guys been machining your own? Is aluminum best or would nylon or a harder acetal plastic work? I don’t intend to make this a full-time job so I’m certainly not trying to go over the top spending money, but I would like to have the tools I need to succeed and enjoy the work. I have always been a saw fanatic and this is just another avenue for me to learn and grow in my obsession.

Lastly, on a side note, I did take a leap of faith recently and ordered a ported saw from a local guy I ran across on the forum by the name of @Stump Shot . I figured with never having run a modded saw, it would be best to start by running one built by someone who knows what they’re doing. Steve has been great to work with so far. He is excellent at communicating and seems to be very knowledgeable. Very excited to get that saw in my hands!
Am working down the list to it, should be a good runner like the others of this model, the 592XP makes for an excellent starting point. :)
You have my number give me a call anytime you like. ;)
 

dthieme

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Am working down the list to it, should be a good runner like the others of this model, the 592XP makes for an excellent starting point. :)
You have my number give me a call anytime you like. ;)
Thanks Steve, I appreciate it. Hope the gtg went well. I'm ooking forward to attending in 2026!
 

Outback

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I meant what ported saw did you order from stump.
 

dthieme

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So last night I got around to tearing down the two parts saws to see what was all usable. To my surprise, one of the saws was actually an 056 super dressed as an AV. The cylinder looks to be in decent shape, but the original mahle piston had a reasonable sized chunk out of the skirt on the exhaust side. There are limited options available for OEM or aftermarket pistons, but I’ve had a positive experience with other parts from Duke’s, so I thought I’d give their pistons a try. Stay tuned for an update on that.

There were some other noticeable differences between the two saws. One of the clutches had linings on the shoes and the other did not. I’d like to do away with the spur sprocket and find a drum with a rim sprocket, but I’m not sure if that’s even a possibility with this model. The super is missing its flywheel and ignition - I’m hoping the one from the AV will fit, but that's TBD. I’ve been struggling to pull the flywheel but hopefully will conquer that tonight. The mufflers were similar - both tall muffler boxes with side exits, but the outlet tube on the super was a bit longer and shaped slightly differently. Anyone have thoughts on these old muffler designs? Any power to be gained here with a muffler mod?

The cylinders were also similar as far as port size and shape, but they had distinct squish band and combustion chamber configurations. Both had offset combustion chambers with a wider squish toward the exhaust side. The plug location on the AV was centered on the bore while the super’s plug was centered on the combustion chamber. The upper transfers were noticeably sloped up towards the intake side of the cylinder and the intake ports had a uvula shaped protrusion on the roof (I believe my 034 AV has a similar intake). Is there any merit to some of these design features?

For the pistons, both saws had domed tops, but the super introduced windows. The pistons also had unique wash patterns (interested in learning more about that if anyone has any insight).

Hopefully will get the chance to time the stock cylinders later this week to see what they’re at. I’m going to start with one of these parts saws as my porting “test rat” and see what happens. Again, still open to suggestions on where to take this build.
 

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dthieme

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jacob j.

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Was debating between the 572xp and 592xp and settled on the 592. Wanted to see how a modern saw compares to my stock 660 magnum. Maybe will give him the nod on a 572 next year lol

The 592 is a good machine, stock or ported so I don't think you'll be disappointed.

The 056 Super is a pretty good runner in stock form. I don't think there's any power differences to be had between the AV and Super mufflers, although I prefer the Super muffler as it gets more heat away from the cylinder. There is a rim sprocket available. I'll see if I can hunt down the Oregon part number or @ray benson might be able to find it in his literature.
 

dthieme

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What you call the “uvula” supports the rings at BDC. I’d let it there.
Thank you for the explanation. I was wondering if that was the case I just hadn't seen it on any other saws besides those two.
 

dthieme

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The 592 is a good machine, stock or ported so I don't think you'll be disappointed.

The 056 Super is a pretty good runner in stock form. I don't think there's any power differences to be had between the AV and Super mufflers, although I prefer the Super muffler as it gets more heat away from the cylinder. There is a rim sprocket available. I'll see if I can hunt down the Oregon part number or @ray benson might be able to find it in his literature.
Thank you, that would be much appreciated. I'm curious how the oil pump drive would work for the rim sprocket. The spur sprocket has a drilled hole in the back that drives a pin which I'm guessing drives the oil pump... I haven't pulled apart the oil pump though so I can't say for sure. If I can make a rim sprocket work though that'd be awesome!

I did get the flywheel off the AV today and found out it has the sem ignition. Not sure if that's a good or bad thing though. Im debating whether I should try to make this ignition work or look for a reasonable aftermarket one. I'm fairly sure my main 056 had a Bosch ignition and I know that one failed. I just don't know if the SEM was any better. Might have to swap it over to the Super and see if it has any spark.
 

ZERO

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Lastly, on a side note, I did take a leap of faith recently and ordered a ported saw from a local guy I ran across on the forum by the name of @Stump Shot . I figured with never having run a modded saw, it would be best to start by running one built by someone who knows what they’re doing.

And a good leap of faith you took.

@Stump Shot is as solid as they get.
Your build will exceed your wildest expectations. Don't ask how I know...

My 372OE on a lazy magnificent seven pulls a 24"/28" like it's a warm up. Glad we had a very open and honest communication on this build, and very glad Steve took this project a slightly different route, at the request of a nagging customer.

Since you are a WI local, you will have some local North Woods goodies dropped in that may have been discussed with the builder.

Steve, glad the GTG went awesome. Maybe some day I will join the fun crowd too. Would love to run them yellows...and sip on some local beer.
 

Mad Professor

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Thank you, that would be much appreciated. I'm curious how the oil pump drive would work for the rim sprocket. The spur sprocket has a drilled hole in the back that drives a pin which I'm guessing drives the oil pump... I haven't pulled apart the oil pump though so I can't say for sure. If I can make a rim sprocket work though that'd be awesome!

I did get the flywheel off the AV today and found out it has the sem ignition. Not sure if that's a good or bad thing though. Im debating whether I should try to make this ignition work or look for a reasonable aftermarket one. I'm fairly sure my main 056 had a Bosch ignition and I know that one failed. I just don't know if the SEM was any better. Might have to swap it over to the Super and see if it has any spark.

There is a fix for the Bosch ignition. You have to pry it a apart and replace a cheap capacitor or diode, I can't remember which?

The "other site" member @foggysail did the fix.
 

dthieme

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And a good leap of faith you took.

@Stump Shot is as solid as they get.
Your build will exceed your wildest expectations. Don't ask how I know...

My 372OE on a lazy magnificent seven pulls a 24"/28" like it's a warm up. Glad we had a very open and honest communication on this build, and very glad Steve took this project a slightly different route, at the request of a nagging customer.

Since you are a WI local, you will have some local North Woods goodies dropped in that may have been discussed with the builder.

Steve, glad the GTG went awesome. Maybe some day I will join the fun crowd too. Would love to run them yellows...and sip on some local beer.

Thanks for the extra encouragement. I had been considering a few other builders when I stumbled across his name on the forum when looking for info on one of my saws. I noticed he was from Wisconsin and his profile said he built work saws. I'm sure glad I ended up picking Steve for my first ported saw. I'm looking forward to the GTG next year and hope I can go. Life has really started getting busy the last year or two and I'm betting that it isn't going to slow down anytime soon either. I've only been part of this forum a few weeks but I can already tell this is a great community. Our country could use more folks like the people in this forum.
 

Junk Meister

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There is a fix for the Bosch ignition. You have to pry it a apart and replace a cheap capacitor or diode, I can't remember which?

The "other site" member @foggysail did the fix.
HotShot over on the over site posted a German UT video showing how to put a Kawasaki (single wire) ignition module on the Bosch ignition modules. The 056AV would originally been a Bosch and the super Changed over midway through production to the sems style. Sems modules need the Sems flywheel and Bosch modules have to be mated with a bosch flywheel. either system can be put on the 045 / 056 AV / 056 Super and 056 Magnums. 056 have a 52mm bore and will interchange with a 056 super (that is 54 mm bore) and the Magnums are 56mm bore and without serious "Tinkering" are in their own league. Do some picture peaking to get an idea on the bay to get a visual of what is what.
 
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