I think I've almost got it.
I finally had a little time to play with the chain saw and I got the fuel line in there.
I thought the old line was a 3/32nds but the new line I got didn't fit through the hole that goes into the gas tank. I tried and tried with a long bevel and just couldn't get it to go, even with WD-40 on the line for a little lube.
I took a 9/64" drill bit and opened up the hole that goes into the tank and with a little more fighting I finally got it to go. It is an extremely tight fit so I'm not worried about a leak there.
The fuel line also squeezes tightly onto the carb.
I believe the old line just had a thinner wall on it than the new Oregon line that I got (the yellow stuff).
When I fished the old line out of the tank it surprised me when I gave it a little squeeze and it just crumbled, no wonder it broke in the first place.
I think I figured out the tension issue too. I believe the head of the adjuster screw was being pressed against the bar and not allowing the bushings on the bar cover to squeeze it like they should.
The housing where the bar studs are attached isn't cracked by the way.
The cover was melted and mangled a little bit right where the head of the adjusting screw is at so I did a little pocked knife surgery and I believe I got it.
You can see the missing paint in this picture from the adjusting screw rubbing the bar.
Here is my pocket knife surgery
Here is the adjuster sitting where it should
I also did a little newbie muffler mod with a flat head screw driver.
The exhaust port goes into a tube with some decent sized holes in it already and that is exposed to the inside of the muffler so there isn't much restriction at all, but the little slit in the side of the muffler had some restriction so I opened it up a little bit with a screwdriver.
Now that I have it back together I ran it and I have a running issue, I think I may have gotten something backwards on the carburetor.
I put the throttle cable and choke lever where it looks like they should go but I have an issue.
In the video you can see that it won't start with the choke off (it was already warm).
If you choke it then it will start and run.
With the choke almost all the way out it will idle.
Push it in and it revs up like you're hitting the gas.
Push it in too far and it dies.
Hit the trigger to release the choke and it revs for just a second then dies.
http://www.youtube.com/watch?v=9GQGpGMove0
I also picked up an 80$ pair of camouflage Stihl chaps that cover the front/sides of my legs and the back is open. They have a pocket on them that holds the two wedges that I got yesterday perfectly.