038 Super to Magnum Conversion

I am expecting delivery of a newly acquired 038 Super this week. I have noticed a few threads recently about this saw and some mention of converting from a Super version to a Magnum version. I have a couple questions if I may.

1. Is it simply a matter of replacing the piston, rings and cylinder jug with a Magnum p/c assembly? Do the mounting holes align or is some alteration required?
   
2. Is any modification needed to the intake or exhaust side?
   
3. What performance improvement is achieved -- from XXcc's to XXcc's by this conversion?
   
4. Is there a benefit to locating a salvaged Stihl (OEM) p/c assy or are the after-market kits comparable? Any recommendations?
   
5. Would I achieve the same results by modifying the muffler to the Super, and would or should I consider a muffler mod for the Magnum?

Ok - that is a good start. Any assistance or guidance you can offer would be greatly appreciated.

Thanks,

GM_DaddyMac said:

I am expecting delivery of a newly acquired 038 Super this week. I have noticed a few threads recently about this saw and some mention of converting from a Super version to a Magnum version. I have a couple questions if I may.

1. Is it simply a matter of replacing the piston, rings and cylinder jug with a Magnum p/c assembly? Do the mounting holes align or is some alteration required?
   
2. Is any modification needed to the intake or exhaust side?
   
3. What performance improvement is achieved -- from XXcc's to XXcc's by this conversion?
   
4. Is there a benefit to locating a salvaged Stihl (OEM) p/c assy or are the after-market kits comparable? Any recommendations?
   
5. Would I achieve the same results by modifying the muffler to the Super, and would or should I consider a muffler mod for the Magnum?

Ok - that is a good start. Any assistance or guidance you can offer would be greatly appreciated.

Thanks,

Click to expand...

1) You have to slot the holes in the cyl/gasket to match the super case. Grind the jug a little so the cyl bolts will seat flush on the base of the jug, and open up the access holes so that the t-27 wrench can get at the bolt heads. Crank, wrist pin/clips, upper bearing are all the same.

2) Intake and exhaust bolts up.

3) 67 to 72cc

4) Good OEM or tecomec

5) I open up the dual port muffler a bit and match it to the exhaust port. Or get the 3 port mag II muffler, these are still available but like the cyl assy $$$$

Thanks!

MP -- thanks for the tutorial. Once it arrives I will check it out and go from there.

Thanks again.

After reading this thread I decided to fit a 52 mm cylinder and piston to my 038avs (50mm piston etc).I had originally bought the saw secondhand and it was well worn barely ticked over,but nursed it along for a season or two but it finally gave up the ghost. Just finished it today and got a run out of it YEEHAH I feel like Dr Frankenstine It fired up after about 3 or 4 pulls and filled the garden with two stroke smoke .Let my creature live !!!

Mastermind (Randy Evans) converted one for me. It is one saw that will never leave here whilst I'm still kickin'

This has a Tecomec topend from Weedeaterman (site sponsor) and Randy's port work & Jon's expert muffler mod

Lots of info. here from Randy. This thread is a straight 038 (non-super) conversion to Mag.
http://www.arboristsite.com/community/threads/turning-a-stihl-038-into-a-ported-038-magnum.207165/

Look at the pix in post #74 in this thread. That is exactly why the 038 will always be here...Old School!

Duane,

Would you choose the saw over an 044 that's been ported as well?

I have a 038 Super that's very clean (180psi compression stock), an OEM 038Mag jug and a meteor ready to go.

I also have 2 044's and an 046.

My buddy's the original owner of an 038Mag from the early 90's. He's a landscaper that walked into his Stihl dealer and said "I need a big saw to cut stumps with". The dealer handed him an 038Mag. He's used the saw in stock form for ~25 years so far, always starts, hasn't even adjusted the carb. This was the first big Stihl I Ever used.

I don't think that the 044 was out when he bought his saw.

drf255 said:

Duane,

Would you choose the saw over an 044 that's been ported as well?

I have a 038 Super that's very clean (180psi compression stock), an OEM 038Mag jug and a meteor ready to go.

I also have 2 044's and an 046.

My buddy's the original owner of an 038Mag from the early 90's. He's a landscaper that walked into his Stihl dealer and said "I need a big saw to cut stumps with". The dealer handed him an 038Mag. He's used the saw in stock form for ~25 years so far, always starts, hasn't even adjusted the carb. This was the first big Stihl I Ever used.

I don't think that the 044 was out when he bought his saw.

Click to expand...

I'm not sure If I have ever run an 044? I do have a 441CM but that is hardly apples to apples.......If you have the stuff gathered to make a conversion, I think you will be very happy with the results. Also, I think you are correct on the timing, 044 followed the 038. Fairly certain they are somewhat lighter and a bit more compact/nimble, (two things an 038 isn't). It is just a brute from yesteryear. Elastostart highly recommended.