Stihl 090 rebuild

[Iron.and.bark]

That's the thing mate, an 090 will take money out of the bank to do properly, unless you get parts at a good deal..

I have 3 husky 394/395's on the go. Will have spent north of $1k in parts to get them running (which will yield a nice profit), but still have to carry the cost till sold.. Big saws = big outlay for potential profit..

Fix and flip other saws and do this one properly for yourself

Oh and you know I'll buy any big dolmars you find.

 

[Brewz]

whats a Dolmar?
Your a sick man!

Yeah I know what your talking about.
The saw haul I got was all big muscle saws.
The smaller ones are gone for a bit of profit but I am finding if you tap the correct market for old saws, the big ones can reap the best rewards.

I will probably keep the 090. Its just something that every enthusiast should have and I have always wanted one.
I guess that's another reason I want to do it properly.

I have a couple others that I have decided to keep that are being sold after receiving good offers.
My efforts to built to a high quality are paying off as people are impressed, tell their friends, then their friends contact me asking if I have saws for sale.

People will pay good money if they know they are getting something good.

Its the unknown that kills a saws value

 

[merlin7734]

Might I suggest... To avoid going Chinese, because a build like this deserves more... Doing something like a fabricated top cover?

Something like this small block Chevy valve cover and keep looking for OEM?

Sent from my MX2020 Secure Satellite Uplink.

 

[Brewz]

Got some time to work on the big girl today.

Pulled the flywheel to get at the ignition so I could fit up a new spark plug wire.
Found this interesting repair.



Looked in the box of spare bits that came with the saw and there was another flywheel, but it is busted.



I also found that the key was worn down and sitting flush with the shaft.
I cut a couple strips of coke can to hold the key up a bit and it worked perfect.



Now have new spark plug wire fitted, ignition module checked and flywheel fitted back up with the key actually holding it in place.

 

[Brewz]

Then I found the locking pin that holds the pull start coupling to the flywheel has been sheared off.

There is not 1 part of this saw that does not need something fixed.

I drilled out another hole, tapped it to 4mm and wound in a bit of 4mm high tensile screw with the head cut off. Added some thread locker for good measure.
Touched the sides down to size and it works great!

 

[Brewz]

Next was the choke flap thingy

The shaft was badly worn and the spring was cactus, so it was flopping around like a rag doll.
I ordered a rebuild kit and fixed it up.

Its as good as new now!

Bent spring and shaft sitting at an angle:





All fixed:

 

[Brewz]

The base plate had a nasty dint in it that was leaking fuel when i got it. You can see where it has cracked through in the bottom of the first photo below.
I ordered a Chinese base and it is fantastic.
Fit and finish are great. Very happy with it.

Replaced the fuel filter while I was in there.

 

[Brewz]

Dug the bar oil tank cover out.
First issue is the aux oiler button has a stuffed o-ring, but I have ordered spares in all the sizes I need for the 076 I am building as well, and a 5 x 1.5mm will seal it.
The saw case flange for the cover had some high points due to dints from its trip off the back of a truck at speed, so I filed it flat to make sure it will seal.

I found that the bottom corner where the wood chips hit was almost worn through, so I used some duct tape to make a dam wall and filled it with JB Weld.
Will remove the tape and file it flat tomorrow once set to make sure there is a good surface area there for the gasket to seal on.

 

[Brewz]

With metal putty setting on the saw, I turned my attention to the poor old handle bar.
It is properly bent, mangled, hacked, welded up crooked and just plain depressing to look at.
Now I know these AV bars are available by the dozen on every corner you turn, but I am up for a challenge and plan to make it good again.

First up I cut off the top bar with an angle grinder and will make a new one from pipe...... it is un-recoverable.
With a trusty propane torch, hammer and vice, I heated, and bashed it back into shape and am very happy with how it ended up.

Will make a new top section and weld it on and when covered in new handle bar rubber, should come up nice.

Before:



This shot really shows just how messed up it is/was/kinds still is


After:

 

[Brewz]

Question.

What is good to use as grip for the handle bar?

 

[hseII]

Question.

What is good to use as grip for the handle bar?

The fellow I bought my 660 from found black hose material that works perfect for handlebars.

@LowVolt ,
What did you use?

 

[Brewz]

hsell, that hose looks fantastic!
It looks like some sort of fuel or oil hose

 

[hseII]

hsell, that hose looks fantastic!
It looks like some sort of fuel or oil hose

It's functional too.

 

[Brewz]

Doing some reading, the little choke flapper thing is actually a governor.
As speed increases, it uses the increased air flow to close off the choke and richen the mix up, stopping over reeving.

The way it was before I fixed it up, it would have been shutting off the choke very easily with the bent stretched spring.
Its much stiffer now.

I have a little tingle of excitement as its looking less nasty after every little repair.

A wise man once told me....... A big job is just lots of little jobs, and this saw sums that up well!

 

[Brewz]

Next major task is to try and repair the top of the cylinder where the spark plug screws in.
I know people suggested milling the top down but I really think all it needs is a touch of devcon in the recess to give a full seal.

Speaking of spark plugs..... does anyone know if the 090 runs on the same spark plug as most other saws of does it need something different?

 

[Brewz]

Its had a helicoil put in but the chunk missing kills the seal.
I plan the fill the gap

 

[nnero]

Nice job so far! I am enjoying following your progress

 

[merlin7734]

My WECSOG mindset says use foam and wrap it in golf club wrap? Not sure that is even something a person can buy?

Nice progress! This is my favorite current build on the site!


Sent from my MX2020 Secure Satellite Uplink.

 

[Brewz]

The repair to the worn case part on the oil tank worked out great!



I dropped by the local steel merchant and found an off-cut bent length of black steel tube exactly the same OD as the OEM handle, just a little thicker.
Got it for next to nothing due to the slight bend in it which didn't worry me as I was planning on bending it anyway.

Bent a section of it over a log round and cut it off a bit long so I can trim it back to the perfect size for welding once I have the front AV mounts fixed up.
Got the motor back on, replaced the fuel lines, and fitted up the new rear handle parts

 

[hseII]

The repair to the worn case part on the oil tank worked out great!

View attachment 26314

I dropped by the local steel merchant and found an off-cut bent length of black steel tube exactly the same OD as the OEM handle, just a little thicker.
Got it for next to nothing due to the slight bend in it which didn't worry me as I was planning on bending it anyway.

Bent a section of it over a log round and cut it off a bit long so I can trim it back to the perfect size for welding once I have the front AV mounts fixed up.
Got the motor back on, replaced the fuel lines, and fitted up the new rear handle parts

View attachment 26315

View attachment 26316

You & I share 2 hobbies, I see.

Lapua is some fine Brass.