RCU Forums - View Single Post - Poulan 46 conversion RUNS again. Pictures Added
Old 04-08-2004 | 09:38 PM
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Antique
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Default RE: Well, here goes nothing! Poulan 46 conversion RUNS.

Get a 2" square of G10, 3/8 thick..Drill a 3/8 hole in the middle..Put a 3/8 bolt in a lathe chuck, bolt the G10 to it..Turn it to about 2'' round..Take out of the lathe, drill the hole to 3/4''. Trace the outline of the oval stub onto the 3/4 hole, it will be almost big enough at the center, but too small to fit the oval..Drill out the brass pulse pressure fitting that sticks out of the flat surface by the oval, tap to 10-32 or 5mm...Enlarge the hole in the G10 slowly to the oval shape, fitting it on the oval and looking for small black marks where the G10 does not fit..Remove the small black marks a little at a time until the G10 fits snugly over the stub..Take the small numbers cast into the flat surface of the cylinder at the base of the oval off until it's completely flat.Take a 10-32 or 5mm short screw and grind a point on the end..Screw the pointed screw into the 10-32 or 5mm hole until only about 1/8 sticks out..Put the G10 on the stub and hit with a hammer to make an imprint with the point into the G10..Drill the G10 with a bit just large enough to clear a 10-32 or 5mm flathead allen screw..Countersink the G10 so the flathead screw is flush..You will have noticed by now that the G10 hits the cylinder fins before it can go all the way down on the stub..Grind off the fin...
Put the carb over the G10 so that the throttle shaft is vertical, that way the throttle servo will not need a bell crank..Mark the position of the bolt holes on the G10 and drill and tap it for 10-32 carb hold down screws...Put Permatex Ultra Copper or 5 minute JB Weld on the stub and flat surface and press the G10 down all the way, securing it with the flathead 10-32..Drill a hole sideways all the way through the stub and tap for
10-32 screws..Put short 10-32 screws through the G10 and into the stub..Grind off flush with the inside the stub..This mount will NOT come off or leak, unless broken completely off in a crash....You will have to tap the case somewhere for the pulse..The transfer port at the rear of the cylinder is a good place, a Du Bro 8-32 brass pressure tap works well..The back cover of the carb has a cast boss not drilled through...Drill it with a #23 drill and press a Walbro fuel fitting in it..Grind the excess brass off on the inside of the cover..Connect the pressure fitting to the Walbro fitting with a short Tygon or seamless black neoprene hose...You can make a throttle arm for the carb shaft from a piece of 1/16 brass flat stock, drilled to fit the carb shaft and soldered on with Sta-Brite...There was a picture of this on the old RCFAQ site,probably lost forever..