Restoring an Old Stihl Chainsaw

Wood Doctor · Aug 8, 2010

I have in my possession a rather big vintage Stihl chainsaw that a friend wants me to restore, circa 1975. It's about the size of a 460 but weighs 18 lb when gassed and oiled up. I have no idea what the model number is because it's worn off the housing. First item on the agenda was to be sure that it ran. It does now, and sounds like a mean demon.

The handle used to have a plastic grip on it, and that's in pieces. The steel handle is about 0.97" in diameter. I'd like to slide on a new grip or wrap it some way. Leaving it smooth would seem a bit slippery.

Any suggestions on how to proceed with a new handle grip? Also, do you recommend any new paint or just try to clean up the old steel housing with a gas bath or turpentine?

Any other restoration tips would be appreciated. TIA.

SpaayDawg · Aug 8, 2010

Pics, we need pics.........

pioneerguy600 · Aug 8, 2010

Sliding on a new rubber grip can be accomplished fairly easily if you can hook an airline to the far end of the rubber hose. Start by sliding the rubber hose onto the handle and then apply air pressure to the hose to cause it to swell, work the hose onto the handle a little at a time, the air helps with the installation greatly.
Pioneerguy600

Stihlofadeal64 · Aug 8, 2010

Post pics and we can direct you as to how to restore the saw. Sounds like you have your work cut out for you, depending on how far you're willing to go. Upload 3 or 4 pictures of the various angles of the saw. This could be fun!

Wood Doctor · Aug 8, 2010

Stihlofadeal64 said:
Post pics and we can direct you as to how to restore the saw. Sounds like you have your work cut out for you, depending on how far you're willing to go. Upload 3 or 4 pictures of the various angles of the saw. This could be fun!

OK, Guys. I will try. Please understand that the saw looks like a truck ran over it. This saw has been terribly neglected. I'll be supplying you with "Before" pictures. Afterwards, when you help guide me, we can take an "After" picture. It started, but I'm not sure how long it will run.

Here are the "Before" Pics. Hope this helps. Only one nut remains that holds the chain/sprocket housing in place:

The guard above the handle flops all over the place and the grip around the steel handle is all but gone, and the air filter and carb housing is loose as a goose:

Note the ignoition switch below is hanging loose. I think it's after market amd doesn't even fit the housing.

As you can see, she's an old bird that wants to fly again. Can you guys help me get her off the runway? Where would you start?

GASoline71 · Aug 8, 2010

041AV... if the bore is 48mm instead of 44mm then it's an 041AV Super.

Gary

Wood Doctor · Aug 8, 2010

GASoline71 said:
041AV... if the bore is 48mm instead of 44mm then it's an 041AV Super.

Gary

Gary, when was this saw first sold? Any ideas? I said "circa 1975" but I was firing from the hip. Was that a good estimate? The owner is an older man who lost his right leg and can't use the saw anymore. He wants desperately to hear it run and and to watch it cut again for old time's sake. So, he commissioned me to rebuld it. He has little money, so I thought I would do this as a favor.

Stihlofadeal64 · Aug 8, 2010

Use some purple cleaner or some Awesome to start cleaning it. The missing bar nut is no problem. You'd be surprised how well this saw will cleanup. If you want to do a full restoration (strip, rebuild and repaint) that is another story all together and many hours. There should be some parts around from some of the guys on here for your saw if something needs to be replaced and/or a parts saw or 2. The 041's are favorites among some, though it is certainly not a lightweight. Congrats on the beginnning of your clean up.

pioneerguy600 · Aug 8, 2010

Not actually shure when the 041 AV`s came out but 75 would be a close guess. There are a lot of parts around for them so no problem finding them. The old 041`s are a classic in a way with a very long production run. Clean er up and let us know what it needs.
Pioneerguy600

GASoline71 · Aug 8, 2010

The 041 rigid frames came out in the 60's... so I would guesstimate 1975 pretty close for the AV model.

I have an 041AV Super... kick ass saw.

Gary

Fish · Aug 8, 2010

This is from one of my old threads, I was going to bump it, but that would be
\digging up old bones....................

Wood Doctor · Aug 8, 2010

Old plastic guard on handle?

Thanks, Fish, Gary, et al. Looks like it's either the original 041 or the 041 AV.

That old plastic guard on the top of the handle flops around loose like a toy and connects to nothing. To me, it serves no purpose and is an obstruction. I have no idea how to save it. Should I leave it that way or remove it completely? What purpose did it ever serve?

KRS · Aug 8, 2010

A '75 isn't an old saw

oke:

KRS · Aug 8, 2010

Wood Doctor said:
That old plastic guard on the top of the handle flops around loose like a toy and connects to nothing. To me, it serves no purpose and is an obstruction. I have no idea how to save it. Should I leave it that way or remove it completely? What purpose did it ever serve?

Which handle?

KRS

Wood Doctor · Aug 8, 2010

KRS said:
Which handle?

KRS

The main wrap-around handle that you hold with your left hand while cutting. The sleeve or grip has all but come apart as shown in the pictures. Only bare steel remains. On the top is this plastic guard that on newer saws connects to a chain brake. This saw has no chain brake so it connects to nothing.

Sprintcar · Aug 8, 2010

That 041 should clean up real nice. There are several Stihl dealerships in Omaha if you need any parts to finish it. Teds Mower service on L street is or used to be a dealership. May have several 041 parts saws, if not several of the other dealerships may have what you need.

:cheers:

pioneerguy600 · Aug 8, 2010

A lot of guy`s on here likely have some odd parts kicking around, let us all know what you need and some of the bits might just show up.
Pioneerguy600

amateur cutter · Aug 8, 2010

Yep, that guard was to keep your hand from slipping into the chain. I've seen guys use bicycle handlebar grips on those saw handles before, seems to work pretty well, I don't know exactly how the handguard is attached on that model, mine has the brake. Just be creative, I'll bet you can up with something. A C

Anthony_Va. · Aug 8, 2010

If you're replacing the rubber grip around the front handle(the handle that wraps around the top) you can buy the rubber tube that goes on it at the dealer.

I will tell you the easiest method to get it on. Take the old stuff off and clean the metal up good. Take the new tubing and put it in boiling water and get it hot. It will slip on there so easy you won't believe it.

I fought with it trying to get it on a 066 handle one time forever and could'nt get it to slip over.An old farmer my dad knows just happened to stop buy while I was doing it and taught me that trick. Works like a charm.

GASoline71 · Aug 8, 2010

The "original" 041 was a rigid frame. The saw you have is an AV model. But if you measure the bore size... you might find out you have a Super...

Gary

Restoring an Old Stihl Chainsaw

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