Stihl 090 rebuild

[drf256]

Great Work Tony.

 

[Brewz]

Thanks mate
I have seen the light at the end of the tunnel and can not wait to get it in some timber!

 

[Iron.and.bark]

Well done mate.

Now get slabbing

 

[Brewz]

Well done mate.

Now get slabbing

The 2100 will be the slabber.

The 090 will be the "just because I can....... I will" saw
Will be great to fire up and scare small children with.

I could move the throttle trigger to the top and use it as a limbing saw?

 

[Iron.and.bark]

72" bar and you have your limbing saw, no need for a top handle... Or a great hedge trimmer.

 

[Brewz]

I would have to sell a child to afford one, but one day!

For now it will get a little tiny 25" bar so I can test it out
Next bar will be a 60" which should cover me for most situations

 

[backhoelover]

Picked up a Stihl 090 today that has had a hard life.
It fell of the back of a truck, has a broken cover, broken AV mount, fracture in the fuel tank and leaks fuel, leaks oil, off switch is broken, spark plug boot is broken, AV mounts are stuffed, rear handle is broken where the top bar connects, tech screws holding the muffler on............ and that's what I found in the first 30 seconds.

But it has finger breaking compression, starts and runs first pull (couldn't believe it!), and has me as a new owner.

It came with a box full of spares that I will lay out and take photo's of over the weekend for you all to identify for me

Thus far I have $200 in it.

I am thinking a full strip, have the damage tig welded, sand blast it all and have it cerakoted in Stihl off white.

The cover has me worried.
Its very thin and I'm not sure if its reparable.
Does anyone know of a replacement sitting around gathering dust?

Also need the 090 part of the badge.

This thread will be dedicated to the rebuild with lots of photos to document it for future generations.

Pics of it as it stands now.

I am in love with it. Its almost as heavy as me and I cant wait to use it

View attachment 22760

View attachment 22761

Happy for peoples advice, opinions, recommendations, help and offers of parts to be posted up here.

Let the fun begin

i really really hate you now use to like you till you got that deal

 

[Brewz]

Oh this was the bad deal of the day
On the same trip I got 9 x 70cc+ husky and Stihl pro saws for $200....... not each...... $200!

 

[Lee H]

Very nice project. Well done.

 

[Brewz]

It works.

Now to repair the top bar section of the handle

 

[Brewz]

New top bar section made, going to go borrow my old mans welder now

 

[Brewz]

Handle welded up and feels great.
Gave the low end a bit of a tune but the governor is an issue.

I will bypass it.

Just need to fix the hole in the top cover now

 

[Brewz]

Any suggestions on what to cover the handle bar with?
I know I have asked this before but I am after further suggestions.
I got some rubber hose but it doesn't want to push over the banged up bar.

Is there a trick?
Its 19mm ID and the pipe is 22mm OD so may be a bit tight.

 

[drf256]

I believe guys hook an air compressor to the hose and push it on. The air expands the tube to aid installation.

 

[Brewz]

I will give that a shot!

Problem is I think this stuff is pressure rated to 200 psi so I doubt it will expand to much, but I will give it a go anyway

 

[Brewz]

The 25" GB Forest king bar will be living on it. Will get a new chain for it soon.
The new spikes are after market and were round on the teeth. I ground then to a point so that actually bite the wood.

I am not going to sell it.
Its to rough and has too many Chinese/repaired bits on it to make it worth anything but after all the work I have put into it, its worth something to me!

 

[Brewz]

I have had issues getting it to idle but I got it sorted this arvo.
Grabbed my tacho and got some really odd readings.
To get the tacho to say 8000 rpm its drowning in fuel and hardly turning.
Lean it out so I sounds better but still rich and it says 14000 rpm.

First time putting a tacho on a saw with points for me...... What's the go???

 

[Brewz]

I am thinking the tacho reads double because I get 1400ish at idle

 

[jake wells]

reinforced body filler might fix the hole in the top cover or a sheet of steel riveted on would make it look like a franken saw.

 

[rogue60]

I have had issues getting it to idle but I got it sorted this arvo.
Grabbed my tacho and got some really odd readings.
To get the tacho to say 8000 rpm its drowning in fuel and hardly turning.
Lean it out so I sounds better but still rich and it says 14000 rpm.

First time putting a tacho on a saw with points for me...... What's the go???

Donno Brewz I've never tuned a saw with a tac myself? sorry am of no help.
Here's a vid of mine for some inspiration maybe?.. They have a bad rap for being slow overseas in small (butter) wood but over here in Aussie hardwood where revs mean nothing and torque is king they hold their own and that be the truth no matter the size of the cut...
Anyways a vid farting about in the wood heap oh yeah wood is red Ironbark.