XL-1 to Super Mini - Auto Oil Pump Conversion Project

[Hoggwood]

I have done this before on earlier blue XL-1's with the manual only pump.  I initially wrestled with the idea while simultaneously converting the crank/rod/piston/cylinder from a Super Mini onto the XL-1.  It became a blue Super Mini XL-1 AO at the time.  West coast BC edition - lol.

I picked up an earlier Super this past week, but it had an XL-1 (blue) drivcase on it.  I wondered what was up.  After digging into it a bit, someone had done a botched job at reassembling it, so it all had to come apart.  In the end, I used the original Super top end, a crank/rod assembly off of an XL-1 AO and a drivecase from a red XL-1.  The PO had put the saw together without the PTO side bearing retainer clips and the crank/bearing had walked all over the place.  So, the original crank/rod and blue drivecase were set aside.  I contemplated using the red crankcase off of the XL-1, but decided I wanted to go with the unfinished on off of the original Super Mini. 

I can appreciate the manual only set-up as intended on the XL-1 drivecases, but I wanted to preserve the Super Mini auto pump feature. 

  
The blanks for the auto pump directly route the oil to the bar pad from the manual pump.  Drill them out like the auto oiler saws.

[Hoggwood]

The wire shows the original path from the manual pump to the bar pad.  The bar pad channel continues to the right in the back of the right hole I drilled.



One needs to block the channel bypass between the left and right auto oiler pump holes now drilled in the drivecase.  Some JB weld and some small drives to work a plug into place.  I just used the bit to keep the JB weld from running into the manual pump to inlet auto oiler (left) hole.    Tap some 8-32 into the bosses for the pump mount.

[Hoggwood]

The casting for the bearing/seal on the drivecase was wider than I recalled on the earlier bue ones.  Or, at least it has been a few years and I don't 100% recall having to modify anything on the pump.  But, the pilot on the XL-1 casting that fits into the rear of the pump was 0.0035" too wide.  Dremel was the best I had to open up the pump diameter.  



Like a glove.  Manual pumps like it should. 

[Hoggwood]

Here is the finished saw, it oils like it should with both manual and auto.  I could still be chasing an erratic ignition issue.   Fingers and eyes were getting tired. We'll see.

[sweepleader]

Nice work, that is dedication to a cause. Well done.