Ryobi 10532 Build - Lots 'o Pics

[Chris-PA]

There really isn't any point to this thread, other than that it is January and I'm bored. I realize these saw's flash in the pan was over before the Earthquake's began, but I had a carcass I got off eBay to donate an engine for my McCulloch. I was smart and got one that had a "bad thing" happen to the handle/tank, so I would not be tempted to rebuild it. Then I put a ported engine in the McCulloch, and Marc (diggers_dad) gave me a good handle, so here we are anyway.

First, some clean up on the intake system. I don't like the way this thing hangs down into the carb intake, so I clean them up (had a hard time with the focus here):

Here it is reduced and smoothed:

 

[Chris-PA]

Next the airbox inlet needed some attention - I enlarged and smoothed it too:

Next, I removed the divider that blocks off the "air injection" system this saw was obviously designed to have:

It picks up air just off the edge of the flywheel fins:

Then I blocked off the other air inlet with some thin adhesively backed Lexan material:

 

[Chris-PA]

Assemble the engine into the chassis:

Handle, A/V mounts and oil pump:

Air valve:

Carb & stuff (new purge bulb):

 

[Chris-PA]

Starting to look like a saw:

 

[Chris-PA]

But it needs a muffler! Naturally it needs to be modified, so I used my usual approach for these. Mark off the back and drill it out:

Once it is drilled the internal baffle is hogged out with a die grinder. The hole in the baffle easily exceeds the area of the port. Then it gets a coat of Ultra Copper to seal it:

A SS sheet for a cover:

A little banging with a rubber mallet:

 

[Chris-PA]

Of course the outlet needs attention:

Final touches:

 

[Chris-PA]

It started and ran, but I had a problem with the seal on the fuel cap and it was leaking. It looks like it just got hard so I will probably pick up a new one.
I have not seen a GZ400 in person, but from pictures and IPL it appears the Ryobi is a GZ400. IMO the GZ400/Ryobi is the best of these saws. It has the better Zenoah air valve, filter and linkages compared to the Jenn Feng built McCulloch.

Compared to the GZ4000 it has a purge bulb, a ZAMA carb with metal linkages, a better choke linkage and a taller filter cover with more room. Otherwise they are the same.

This engine is mostly stock, except for a bit of spark advance, deleting the base gasket (squish is right at 0.020"), and blending the lower transfers to match the case, similar to this one:

I've already run this engine and it works well, so assuming nothing else goes wrong it should be a nice saw.

 

[kyle.kipple]

Video?

 

[Chris-PA]

Video?

Hey, it was getting dark and I was cold, plus the way it was leaking gas the video might have gone viral - "Idiot lights self on fire with chainsaw"

 

[blsnelling]

Those little saws mod great. The one I did was the strongest 40cc saw, sub 9 1/2 lb saw I've ever built. I'd love to get my hands on a GZ4500 someday. Nice work!

 

[naturelover]

Well, had it caught fire, you woulda fixed your dark and cold problem at the same time!!!

 

[Chris-PA]

Those little saws mod great. The one I did was the strongest 40cc saw, sub 9 1/2 lb saw I've ever built. I'd love to get my hands on a GZ4500 someday. Nice work!

Thanks! I remember that thread, I just re-read it the other day. I have three of them now and I really like them. And I'd love to run a GZ4500 too.

IIRC the only difference in the engine between the 4500 and the 4000 is the piston, cylinder and ring. I looked into getting the parts to upgrade mine when it ate a rod bearing and I think it was like $110. But then if you want to convert it to 0.325" you need the sprocket and pump gear, and that adds quite a bit.

The 40cc units are much more common and parts are a lot less and more available.

 

[Chris-PA]

Well I ordered a new fuel cap, but it may be a while until it ships. In the mean time I found some scrap neoprene sheeting of the right thickness at work and cut a new gasket for the old cap. Now I just have to wait for the weekend to see if I can try it out. The weather will not be helpful. Maybe I should pull the top cover and set it up for carb heat.

 

[Chris-PA]

The RedMax extended family - YellowMax, BlackMax, GrayMax and cousin Earthquake:

 

[diggers_dad]

Well I ordered a new fuel cap, but it may be a while until it ships. In the mean time I found some scrap neoprene sheeting of the right thickness at work and cut a new gasket for the old cap. Now I just have to wait for the weekend to see if I can try it out. The weather will not be helpful. Maybe I should pull the top cover and set it up for carb heat.

Can you cancel the order? Do you have any idea how many of those "parts saws" I have? I can get one in the mail on Monday. Shoot me a PM if want it.

Come to think of it, I might just send you a few more "extra parts" so you'll be forced to build yet another one ... That's just the kind of guy I am.

dd

 

[fuzz1500]

Cool pics and info man !!! I love the saw family pic !

 

[Chris-PA]

Can you cancel the order? Do you have any idea how many of those "parts saws" I have? I can get one in the mail on Monday. Shoot me a PM if want it.

Come to think of it, I might just send you a few more "extra parts" so you'll be forced to build yet another one ... That's just the kind of guy I am.

dd

It's OK - the one I fixed is actually working great. I also got a couple of the oil pump lower hoses, as they are better than the ones on other similar saws, and it was like $10 with shipping. The rubber degrades over time if exposed to certain fuels.

I really appreciate the parts - it all cleaned up really well. I assume you got the starter? I was looking at that orange McCulloch in the shop tonight, and I still can't believe JF made that saw with the strato ports blocked off. I started thinking about ways to modify it and then had to kick myself!

 

[diggers_dad]

It's OK - the one I fixed is actually working great. I also got a couple of the oil pump lower hoses, as they are better than the ones on other similar saws, and it was like $10 with shipping. The rubber degrades over time if exposed to certain fuels.

I really appreciate the parts - it all cleaned up really well. I assume you got the starter? I was looking at that orange McCulloch in the shop tonight, and I still can't believe JF made that saw with the strato ports blocked off. I started thinking about ways to modify it and then had to kick myself!

Nobody likes a quitter.

That line-up needs an orange saw.

I have the stuff to make it strato...

 

[Chris-PA]

Nobody likes a quitter.

That line-up needs an orange saw.

I have the stuff to make it strato...

Nooooo... LOL. I do too, but the air valves won't fit to the case. It probably runs fine the way it is, but how could I run it knowing those strato ports are in there and blocked off?! That would just be wrong! Then I wondered why they didn't feed the strato inlets with fuel mix from the carb? That would be easy.

 

[diggers_dad]

Nooooo... LOL. I do too, but the air valves won't fit to the case. It probably runs fine the way it is, but how could I run it knowing those strato ports are in there and blocked off?! That would just be wrong! Then I wondered why they didn't feed the strato inlets with fuel mix from the carb? That would be easy.

Ah....

A few more parts from an old Ryobi might fix that little issue. Then we need to figure out how to convert it to .325. Next comes fuel injection, then 4 wheel drive, and we'll need an electric start. I'll get some parts boxed up right away.