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McCulloch Chainsaw Handle Repair

Shaped bolt head

Shaped bolt head

We acquired a McCulloch chainsaw from a friend in “Used to worked fine” condition. I hate small internal combustion engines, two-strokers in particular, but sometimes ya can’t look a gift horse in the orifice.

Anyhow, the only real repair needed was a new bolt for the anti-kickback clutch handle. For unknown reasons, McCulloch uses a non-standard head that, fortunately, can be carved out of a stock bolt.

Reshaped bolt in place

Reshaped bolt in place

I got the two parallel sides a bit closer together than was required; if I were to do it again I would squish some modeling clay into the recess, make some measurements, and get it right the first time. I’m certain the original was much fancier, but this will suffice.

Nylock nut on trimmed bolt

Nylock nut on trimmed bolt

Trim the bolt to fit and a nylock nut on the outside should hold it in place forever more.

The repair was prompted by a late winter storm that dropped a huge branch from our neighbor’s tree next to the house. We’d splurged on underground utilities when we upgraded the service entry to 200 A and this is exactly why…

[Update: A great and completely off-topic discussion about schematic & PCB programs showed up in the comments. I’ve extracted those into a separate post so folks can actually find the discussion with a sane set of search keywords…]

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  1. #1 by randomdreams on 2010-04-27 - 15:39

    There are few words I hate more than “nonstandard hardware”. That’s a nice fix for an incredibly irritating design decision. I recently had to lathe a piece of steel with a non-standard thread both externally and internally to fix a perfectly good hatrack with a poorly-designed bit that attached the stand to the base, and I had a great list of uncomplimentary things to say to the mechanical engineer who put that together.

    Offtopic: have you ever used gEDA for schematic or pcb? I’m looking for something with reasonable abilities, and the crippled demo versions of orcad, eagle, and winqcad all look fairly crippled. I’ve zero use for autorouters and autoplacers (because they suck for analog design) but it’d be nice to have something that’s fairly usable for schematic and layout.

    [Ed: Go there for more on schematic & PCB programs…]

    • #2 by Ed on 2010-04-27 - 18:09

      lathe a piece of steel with a non-standard thread both externally and internally

      Talk about Quality Shop Time!