Stihl 045 case missing a chunk, lost cause?

[Tom Dakan]

I have a stihl 045 super ii that I bought a few years ago. It basically worked fine but could be a bit fussy about starting so I decided to tear it down, clean the carb, check the piston and clutch for wear, etc. And then life happened and I'm just now getting back to it. I was reading through the service manual again tonight and noticed a section where they basically do a leak down test on the crankcase. When I bought it, there was a chunk missing from the clutch side case where they meet up. It didn't seem to leak a crazy amount of oil so I figured it was fine.

Can anyone confirm whether this is a problem or not? And if it is, is there a realistic way to fix it (that doesn't require being able to weld magnesium and and machine the edge of the case flat.

 

[cbfarmall]

I wouldn't say your case is junk. Any leak there there would be coming off the pump itself-it has a couple seals. It shouldn't be hard to find a good case to replace that one, however. Certainly, that missing bit will have not affect how well your saw runs.

 

[Vintage Engine Repairs]

Just cosmetic I’ll forget about it

 

[Woodslasher]

I wouldn't say your case is junk. Any leak there there would be coming off the pump itself-it has a couple seals. It shouldn't be hard to find a good case to replace that one, however. Certainly, that missing bit will have not affect how well your saw runs.

Old Stihl case halves need to be a matched set, ask me how I know.....

 

[hotshot]

You can use layers of JB Weld & window screen or sheet metal to fix that ‘non-structural’ hole.

I once did a rotted lower mount edge on an 045 a few years back, in three or four layers. Grind it down to good magnesium & have at it, lol. Sand it flat, primer, paint & sand it out again dirty/wet if you want it to match the existing bottom half.

It’s still going strong after 4 years, even when reefing it out of a pinched log cut.

I forgot that I Dremel cut the silver muff open, gutted the rattling baffle out, and tig welded it back together. I’ll never do that tedious task again!

 

[Vintage Engine Repairs]

I repaired very similar damage to yours, go for it, but it’s not necessary functionally, if it doesn’t bother you.

 

[Tom Dakan]

Thanks all! I was chatting with someone in a local metalworking messageboard and they're offering me a free, almost complete, 056 for parts so I can blend the saws together and get something working. Since the broken bit is pretty much cosmetic, I'll try patching it and see how I get on. Maybe I can't get two decent-looking saws out of it.