Is this repairable or replace? pp295

[paulyb21]

Hi there reading the posts for a few months now especially enjoy the Poulan thread...

I picked up a used poulan pro 295-3 (Have a PP180 that still runs great expect for mediocre chain oiling now)

However after getting it running and while setting up the carb I heard some clicking and shut it down. (note to self when buying used and the chain is installed backwards, double check everything else!!!)

The cylinder lug to hold one end of the ignition module has snapped off and the module was riding the flywheel

View attachment 146870

Question can this be repaired: welded, brazed, jb weld-ed or clamped etc or do I need to buy a new cylinder????

Module is still firing but need to firmly reattach. Piston looks good enough through the exhaust port, but can check further once I get the "jug" off, never done this before but there are some similar posts that I have been reading. Guess this is what they call a clamshell design?
Any comments or advice would be welcomed

Thanks Paul

 

[pioneerguy600]

I hope those are casting marks and not cracks in the flywheel. Yes that boss could be welded back on by a good experienced welder. It may be possible to make up a bracket that would bolt in under another bolt somewhere and let the bracket extend out to where the boss broke off.
Pioneerguy600

 

[Arrowhead]

Yes it's a clamshell. If there is enough meat left on the cylinder, you can drill and tap it and go with a longer bolt. I would drill out the piece that broke off a little larger ( so the bolt slides through it) and use it as a spacer.

 

[Modifiedmark]

That don't look good at all and I have a few doubts about it.

If I were mine I think I would do like Ed suggested but beware that spot is thin to be drilling in. You will need a bottom tap as well to get threads all the way to the bottom and then get a bolt just long enough to tighten but not bottom out.

I also think I would bevel the broken piece before bolting on and then JB weld it after it was bolted in place.

Like I said I have my doubts, but you aint got much to lose either.

 

[Trigger Man]

I hope those are casting marks and not cracks in the flywheel. Yes that boss could be welded back on by a good experienced welder. It may be possible to make up a bracket that would bolt in under another bolt somewhere and let the bracket extend out to where the boss broke off.
Pioneerguy600

Good eye Jerry, they look like cracks to me.

 

[pioneerguy600]

Good eye Jerry, they look like cracks to me.

The way they look to travel from the outside in toward the magnets makes them look like cracks from here. For that boss to get snapped off I think the whole engine may have been hit from the side.
Pioneerguy600

 

[Modifiedmark]

The way they look to travel from the outside in toward the magnets makes them look like cracks from here. For that boss to get snapped off I think the whole engine may have been hit from the side.
Pioneerguy600

Or they might have been caused when the coil caught it?

 

[Saw Dr.]

Good eye Jerry, they look like cracks to me.

:agree2:

Probably not too hard to find another flywheel,,, or coil,,, or cylinder. All 3 makes it a pretty tough one to swallow. If you end up splitting the engine to change the cylinder, you may find bad news in the crank seal department also. How far are you into it already?

 

[paulyb21]

replies

Pioneer guy yes those are casting seams in the photo, not cracks It did scrap/scuff the edge a bit though. Things happen pretty fast at a few thousand rpms. I'll pull the drive clutch off and get the cylinder off soon. May drag it to town tomorrow and see what the welding shop thinks

Arrowhead not sure if there is enough metal left there, sheared off pretty flush Wish it was old style with some head bolts, could peep in there pretty quick to see whats under the spot. Might be transfer port???

Modifiedmark, ya not much to lose to try... new jug it twice $$ what I paid sofar...

Paul

 

[pioneerguy600]

Or they might have been caused when the coil caught it?

I don`t see any marks on the flywheel vane indicating it was caught, the coils usually just ride around on the flywheel circumference when they come loose, seen many that have and they just leave score marks in the surface of the rim.
Pioneerguy600

 

[paulyb21]

good ideas

Good ideas guys, I'm partial to the bracket and dentistry crown work approach If you try the JB weld you could use a small 1/16" drill or smaller and install 4 or 6 wire dowel pins at the joint if the welder thinks he'll do more damage than good.
(pun intended)

Question, is JB weld good for the high heat of a cylinder? or is there a different product
Paul
ps guess I should proceed and tear down the engine?

 

[paulyb21]

It may be toast, but it was cutting wood,

Hi got the cylinder off
Exhaust side of piston looks good...

however... intake side looks beaten up

here is the clylinder

and closer, sorry not the best focus

So here are tonight's questions...

1 can this cylinder be cleaned up??
Looks a little sick to me, I can even feel a little nick under the bottom of the intake port on the cylinder.

2 can this piston be buffed out?

3 Can I buff both up best as possible and just try a new ring $7)(p/n530037380) and hope for the best ( its only for me,)???

4 or If I go with a new piston and ring kit (about $45) Will reusing this cylinder damage them???

5 Take up fishing and use this as my boat anchor?

What would YOU do??!! ( I went and bought some JB weld today, welding is not an option)

Thanks
Paul
ps and yes I feel a little discouraged right about now, and sorry for all the questions
pps oh ya the chain sprocket is a little beaten but should live til the chain and 20" bar wear out; photos coming of that soon
pps never trust an engine been sold without an air filter installed

 

[8433jeff]

Yeah, when I seen the intake side I wondered if the air filter was around or in the trash can yet. Arrowhead knows his Poulans, as does ModifiedMark. I say wait for another to come along, as this one is toasted. But its your moneys, spend 'em afor the guvment gets 'em.

 

[paulyb21]

better pic of intake damage

Here is a better picture of the intake side of cylinder
P

 

[paulyb21]

:agree2:

Probably not too hard to find another flywheel,,, or coil,,, or cylinder. All 3 makes it a pretty tough one to swallow. If you end up splitting the engine to change the cylinder, you may find bad news in the crank seal department also. How far are you into it already?

And now piston as well. Amazingly seals look good but who knows for sure? eh Sort of dead it my tracks right now, looking for some used parts in the local area. l am new to this game.
Not sure how to proceed. Can I dremel out the damaged cylinder chips and try used piston? or am I chasing my tail?
Thanks

 

[dh1984]

yea that cylinder and piston is tosted i had one just like that and the the bolt that holds the handel in place took and broke and then i just took and drilled it out and i fixed it untill mine then i just took and replaced the whole saw with a poulan 4218avx but i wished i had my poulan 295 back it was a beast in the wood

 

[blsnelling]

I just blew the pic of your flywheel up 300%. Please inspect it closely before using it. Those REALLY look like cracks to me!

 

[8433jeff]

You look like the Tasmanian devil; stop now before you are even dizzier. Wait; these saws are all over, you might have more than you care to before long. Its your money, you can say I fixed it and have an empty pocket, or you can say Next saw please, thank you very much. Remember, the junkyards are full of things that ran surprisingly well just a few days ago, but its still only parts now. Maybe really good parts, fondly remembered parts, parts from my first whatever, but still only parts.

 

[paulyb21]

I just blew the pic of your flywheel up 300%. Please inspect it closely before using it. Those REALLY look like cracks to me!

Hi Brad possibly a mute point now (unless the parts god drop a parts saw in my lap)(trying to find out what models have parts that can be used)

Looked at the flywheel and the photo that I used, there were some fibres stuck on the flywheel. Didn't do the best job prepping it for the photo, oops, sorry for the mis-lead, but thanks for your attention to checking it thoroughly.
Paul

 

[blsnelling]

Hi Brad possibly a mute point now (unless and parts god drop a parts saw in my lap)(trying to find out what models have parts that can be used)

Looked at the flywheel and the photo that I used, there were some fibres stuck on the flywheel. Didn't do the best job prepping it for the photo, oops, sorry for the mis-lead, but thanks for your attention to checking it thoroughly.
Paul

No problem, just didn't want to see you get hurt.