Poulan 245A Resurection

I have to admit, I am starting this thread for selfish reasons, but I also think it will be useful to other folks as well. I need one thread where I can post questions and update you all on the progress of my project. I started in the Poulan Sticky. I just need a single thread on this for my own reference where I don't have to page through hundreds of other posts. What can I say... I'm lazy! :hmm3grin2orange:

This is where I started: http://www.arboristsite.com/chainsaw-stickies/98495-385.htm#post2586756

I've cleaned up the piston enough to get it to a useable state. No slop in the cylinder at all. Ordered new rings from Ottos Engine Works, and then started asking a bunch of questions. Did the ring gap filing tonight as it was raining and I couldn't work on the other projects.

Started out with the rings @ 2.010. The bore is 2.005". Plus there is a pin in the ring groove that needs to be accommodated for. I set up the ring in a small vice, and then used a file to slowly grind it down to the correct gap (between .04% and .08% of the bore-- thanks jerrycmorrow).

Ring in vice: View attachment 294524View attachment 294525

Next, I put the ring in the cylinder to measure the gap:View attachment 294526

Then used the piston to ensure the ring was sitting square in the cylinder:View attachment 294527

Lastly using a feeler gauge I measured for the correct ring gap: View attachment 294528

All and all it was an easy task. Not sure why it took me so long to get started. Next, I have to remove what's left of the base gasket of the cylinder (who has pointers?). Then check the squish. Then put it all back together. Sounds simple enough, but will take me a long time. Getting that gasket off and then the wrist pin in and out a few times is going to be a pain in the neck!

Good going. Glad to see the thread.
Regarding the base gasket, I've not found an easy way yet though there has to be one. I always use some elbow grease, razor blade (held with the cutting edge flat to the surface), brake cleaner, anything else I have handy that I think will soften the gasket. Gotta hold your tongue just right and make sure you don't gouge the mating surface. I also work concentrically so if I do slip I don't gouge across the surface and make a direct path for leakage from the jug to the outside world

Besides the liquid and spray on gasket removers I have used paint and varnish remover, the gel type will remove gaskets, Tal Strip works well on aluminum.

Telemaster, thanks for the thread :msp_thumbup:! Hopefully it will be useful to me when I tear into my Poulan (Dayton) 245SA.

Are you a musician (Fender Telecaster reference?)?

245A was my first saw, bought new in 1977. Great old saw!