Saving a Poulan 4200/5200 air fliter

Modifiedmark · Apr 7, 2012

Since these are NLA and expensive when found NOS I finally got around to trying out a idea I have had for fixing these filters with wore out flocking.

I first removed the old flocking with high air pressure then a wire brush. After that I used the filter half for a pattern and cut out some Max flow filter material to fit inside. Had to cut out the holes in the material to fit the openings inside then used a hot glue gun to fasten the material inside the filter halves.

This was my first try at it and can probably do better the next time but this should work ok. I was concerned about the glue if it contacted any fuel but I put some glue on a piece of wire, let it cool/set then dunked it in a can of gas for a bit. The gas didnt seem to affect the glue any at all.

Next time I get my 5200 out I'll give this filter a try.

discounthunter · Apr 7, 2012

looks good. ever try filling one with the green foam filter material? my 143 is running like that,so far so good.

3000 FPS · Apr 7, 2012

For an obsolete part I think it looks pretty good and it really should work well. The hot glue looks like it formed a good seal so it should not be a problem. Good idea Good job.

Modifiedmark · Apr 7, 2012

I had thought of the foam filling but figured the air would have to pull a long way though it after it plugged right above it.

I dont know how to explain that any better I guess.....

rms61moparman · Apr 7, 2012

I really hope that works because I have probably a half dozen of those filter cases with the flocking gone in varying degrees!!!
Be sure to post up how it does.

Mike

cbfarmall · Apr 8, 2012

Mark,

Looks good.

Is that the filter material I gave you?

Chris B.

Modifiedmark · Apr 8, 2012

I debated gluing the filter material to the outside. After doing this one on the inside I'm hoping that junk dont get between the screen and the filter material as it dont lay completly flat on the inside.

Time will tell.

Modifiedmark · Apr 8, 2012

cbfarmall said:
Mark,

Looks good.

Is that the filter material I gave you?

Chris B.

It is, I finally got around to buying a hot glue gun LOL. Thanks again.

67 Mustang · Apr 8, 2012

Looks good, Mark! I've got a couple of those to try out myself. Thanks for the thread. :msp_thumbsup:

Warped5 · Apr 8, 2012

It does look good, Mark! :msp_thumbsup:

After we spoke a week ago, I got to thinking as well ... :msp_confused:

I found a B&S pleated air filter in the $.99 bargain bin at the hardware store and flattened out that material before gluing to the OUTSIDE of the filter box. Seems to work well thus far.

I reasoned that the foam I had in my parts box would be too restrictive ..

The one thing I did notice was that the glue gets a little bit brittle and doesn't especially like to adhere to the plastic of the filter frame. I applied enough of a bead to get the glue into the screen a bit.

A couple of other (more commonly available) filters arrived in the mail yesterday ... I will post later today if they fit up OK.

OhioGregg · Apr 8, 2012

Great job on that Mark. Back when I first got my 5200, the flocking was at least 75% gone. It scared me to use it that way. So until I could find a new one that didn't cost me an arm & a leg, just an arm.:msp_mad: I tried the wire brush method and used some foam material I had around. While it got me by until I found a new one. Seemed to me that it was only drawing and filtering right above the carb opening. Instead of using all the available filter space.

Gregg,

Modifiedmark · Apr 8, 2012

Gregg, thanks for posting that up, it explains what I was trying to say. Yeah it works with the foam but not that well.

Justsaws · Apr 8, 2012

Keep an eye on the hot melt glue over time. Exposure to fuel can make the general purpose glues degrade and become brittle. If it discolors you might want to remove it and find a solvent stable glue or epoxy.

I have had better long term success with Dirko than with HMG and epoxies worked best.

I wanted to add that if possible it is a good idea to attach the new filter material to the outside of the old filter. Having worked on more than a few saws that sucked the foam and or mesh into the intake and in some cases all they way through the saw it is something that is worth considering. I know that old brittle HMG will straight up make a heck of a mess inside a P/C and most likely would not have been an issue if it was applied to the outside of the exsisting filter.

Dan_IN_MN · Apr 8, 2012

Justsaws said:
Keep an eye on the hot melt glue over time. Exposure to fuel can make the general purpose glues degrade and become brittle. If it discolors you might want to remove it and find a solvent stable glue or epoxy.

I have had better long term success with Dirko than with HMG and epoxies worked best.

Hot melt glues are really a thermoset plastic. Hot-melt adhesive - Wikipedia, the free encyclopedia <--good article IMO....there are many different HMGs. FYI There might be one that works better with fuel.

Justsaws · Apr 8, 2012

manyhobies said:
Hot melt glues are really a thermoset plastic. Hot-melt adhesive - Wikipedia, the free encyclopedia <--good article IMO....there are many different HMGs. FYI There might be one that works better with fuel.

I left a 1" diameter stick of LTLW packaging glue on the dash board once, opps.

Metals406 · Apr 8, 2012

Check this out: TWIN AIR Dual Stage Twin Layer Foam Filter Material 600x300x15 Cut Out Ur Filter | eBay

Modifiedmark · Apr 8, 2012

Justsaws said:
Keep an eye on the hot melt glue over time. Exposure to fuel can make the general purpose glues degrade and become brittle. If it discolors you might want to remove it and find a solvent stable glue or epoxy.

I have had better long term success with Dirko than with HMG and epoxies worked best.

I wanted to add that if possible it is a good idea to attach the new filter material to the outside of the old filter. Having worked on more than a few saws that sucked the foam and or mesh into the intake and in some cases all they way through the saw it is something that is worth considering. I know that old brittle HMG will straight up make a heck of a mess inside a P/C and most likely would not have been an issue if it was applied to the outside of the exsisting filter.

Thanks for all the good points. Like I said this is just a trial to see how it works out. I also thought about putting the filter material on the outside as well but have to figure out how to make it set down on the carb itself.

As for the glue sticks, you maybe right, it might not hold up over time but I was encouraged by the sample that was left directly in gas for about 20 minutes without any apparent adverse effects.

A good two part epoxy in those tubes that mix as you apply them might be a better idea especially if the filter material was put on the outside of the filter housing.

tomdcoker · Apr 8, 2012

saw

[SUB][/SUB]View attachment 232792

procarbine2k1 · Apr 8, 2012

Thanks for posting this Mark. I will be doing the same this week. Looks like a clean job to me, and there isnt much to lose on a filter with little to no flocking sitting around.

tomdcoker · Apr 8, 2012

saws

View attachment 232793

I know that this is the wrong saw for this thread, but I finally was able to post a picture that is open thanks to Nick. Tom

Saving a Poulan 4200/5200 air fliter

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