How to Port A Chainsaw

Most chainsaw owners are happy with the amount of cutting power they can get from a gas-operated chainsaw engine. But many of us are tinkerers, and the ability to increase the power of a chainsaw-engine is too tempting a project to not undertake. This is not an easy process, however, and it requires the knowledge, tools and skills necessary to manage this intricate tasks. Here is a step by step guide as well as a list of supplies and tools you’ll need to port a 2 Stroke cylinder for a gas-powered engine.

What you’ll need:

  1. Safety goggles
  2. Work clothes or apron to protect your skin from any metal or aluminum shavings
  3. A rag to wipe off spilled oil.
  4. Measuring calipers
  5. Metal file or file bits for an drill
  6. Air tool with an air cutter or other bits or electric drimmel
  7. Flashlight
  8. Various other standard tools (screwdriver, hand tools, etc)

Be very cautious and careful when working on your chainsaw. The main task you’ll concentrate on is filing away the aluminum edges of parts of your cylinder on the inside and side – either will a hand file or drill-powered version. Removing additional material is easier than putting it back on.Try to find similar extra parts for the model of chainsaw you have.

Disassemble your chainsaw and isolate the stock cylinder. Your step is opening up the cylinder wall at the port to your desired width. When filing the actual cylinder port, try not to file away too much material from the bottom or top of the port. This could mess up your timing and you won’t see any performance gains. Try finding another cylinder that has been previously altered to the dimensions you desire and use it as a guide while taking most of the material off the lateral edges. Make sure you only go as far as the piston will allow you to on the side of the skirt to prevent gases from escaping underneath the piston, killing your performance.

Next, you want to take away any bit of air turbulence you can find. Make the inlet side of your intake port of your cylinder slightly bigger than the outlet side of your intake to create the most amount of restriction right at your cylinder wall. This included filing away any unnecessary ridges or port work so your intake wall is smooth. Repeat this same process with the exhaust port of your cylinder, making the inside opening bigger than the outside port opening and smoothing the wall out.

If you complete this process and still don’t see a significant increase in your chainsaw’s performance, you might also want to port out the muffler of your chainsaw. A good rule of thumb is about 70% of the area of your exhaust port. But this process is more than just taking the screen out and opening up the exit hole. You also have to bolt up a gasket and match it to the opening of your exhaust port of your cylinder first. Then you can bolt it onto and match it (by adjusting or filling this gasket) to your muffler second. This will ensure that the air coming from the exhaust port is not getting impeded when going into your muffler. You can also open up the baffles in your muffler to make sure no air gets restricted there. Check your compression so you won’t be hitting the top of the cylinder and make sure you don’t get too much compression (which could damage the engine). Another good suggestion is to sand your decking and putting a thin gasket on to see where your at in the process.

Also read: How to Measure a Chainsaw Bar

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