Very nice post, and nice work. I know you went to a lot of work to present it as you have, and I for one appreciate it. I "feel your pain". I too have posted things I thought were pretty cool that took a lot of work to present, and got very little to no response sometimes. Don't feel bad. It's not you, it is just that some of the work we do is well beyond the capabilities of the average engine converter, and also the fact that this forum is "dying" anyway because the influx of cheap Chinese engines has all but killed the will and desire of the average person to bother with a conversion. It's a shame because now that the price of CDI ignitions has come down so much, these engines are more viable than ever, and will definitely outlast any Chinese engine. Oh well...
Anyway, once again, excellent post. I have some more to say about it, but I want to find some pics of the same conversion that I have done myself to add. Mine was considerably simpler, but it worked well on several conversions of these engines. As a matter of fact, I have one on the workbench to convert right this moment. The Poulan 42cc is a good engine, and you are correct in that the 33cc is almost identical, at least from a conversion standpoint. However, the Poulan 46cc is a completely different engine. It has been popular in the past with the conversion crowd, because it is a bit lighter, and it does not require using electronic ignition as the mag coil is mounted on the engine instead of on the saw body as the Poulan 33/42cc engines are.
So, more pics later on when I have time to search for my pics. I've changed computers a couple of times since I last did one.
Enjoy your hard efforts, I've had many, many good flights with Poulan engines. Ah, one caveat for prospective converters of the Poulan engines though. Be sure to check what you are getting before you buy. The later Poulan engines had the smog, two barrel carb setup, and I have seen MANY of these burnt up because they are set to run so lean. As always with a two stroke engine, it is best to take two minutes and pull the muffler off and have a look inside before buying....
Meanwhile, to me at least, it would be interesting to see some pics of your muffler fabrication.