Stihl 036/044 Hybrid Build (2024)

Hi there, just wrapping up some loose ends on this build. There were some ideas kicked around in this thread about what would be needed to be done to make it work
http://opeforum.com/threads/calling-stihl-hybrid-builders.9593/
I had a bunch of spare 036 parts that needed some new life and the local CT GTG coming up so decided to give it a shot.

First the cylinder mounting holes need to be slotted just like a 044/046 hybrid. To address the 2mm shorter stroke, about
.100” needed to be removed. Mattyo took .050” off both the case and the cylinder( thanks Matt!) I also got a spare hyway 044/ms440 cylinder from him. I’m using a 044 hyway piston(10mm pin to fit the 036 crank)

The larger piston (and longer skirt)was too large to fit down into the case so a little clearancing around the skirt area is needed.
The piston comes close but does not touch the crank.
After cleaning up and widening the intake and exhaust I ended up with
100, 120, 80 for port timing

Next needed some material taken off the outside of the transfer port to clear the flywheel and a few fins trimmed to fit the original plastics

Still need to drill and tap a hole for a threaded stud to secure the top cover.
Decompression port lines up perfect.
Still working on handle, using 044 carb swapped on. Will update tomorrow.

Chainsaw Jim said:

I've been waiting to see someone do one of these. Nice looking saw to start with.

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It was an ok case but it had bad bearings and a bad crank. Trying to build this on the cheap so a chinesium crank/bearings were used.

Awesome work.

Thanks for the Trailblazing.

T.Roller said:

Numbers landed in a great spot. Should be one hell of a runner. What carb are you running?

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It’s going to use an 044 carb

So if you are not familiar with the 036/ms360 carb, it has a strange linkage setup. The carb is upside down compared to many other stihl carbs. The throttle and choke levers are on the top and the compensator/intellicarb port is on the bottom. Here is a pic of the weird stock setup, throttle goes behind, up and around the back of the carb, choke it pushed by the linkage in the front.

When using the 044 carb you will have to create new throttle and choke linkage.
Throttle linkage was easy. Used a stock 044 linkage, just cut it shorter on the trigger side and put a new 90 degree bend in it to insert into the trigger. I did need to grind away an area on the handle itself, behind the throttle lever on the carb to allow full movement. Choke linkage was not so easy. I ended up screwing a small eye bolt into the plastic position switch rod and making new linkage to attach to it from some really small RC car swiveling rod ends I got from the local hobby shop. They did need to be cut slightly shorter to fit. They are plastic so they are easy to work with. They are connected together by a very short piece of #4-40 threaded rod. (You could also use 3mm rod, the ends do not come internally threaded so you can use either size) If anyone needs any of the linkage it was Traxxas part # 2742 and comes 6 in a pack. The stock fuel line fit, I cut it slightly shorter. The brass fuel barb did need to be turned and angled down slightly and I also cut about 1/8” off the brass fuel barb to prevent the line from kinking. The 044 carb also has the impulse below the carb. luckily it lines up with a recess behind the handle where a line can fit in. So just drilled and pulled the line through. I used a 029 impulse line here ( 044 seemed a bit short). I’m going to be using an 038 boot. Seems to fit slightly better than the 044 boot.

Working on fitting the exhaust next. Going to need to make a 1/4” thick spacer to get the stock muffler to fit.

Dub11 said:

I so want to do this to a 036 I have setting a box that I really don't feel like putting back together for fear of a major case of "meh".

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That was basically my reasoning as well.
But this thing could still end up being a turd
so we will see what happens.

J_M____ said:

So if you are not familiar with the 036/ms360 carb, it has a strange linkage setup. The carb is upside down compared to many other stihl carbs. The throttle and choke levers are on the top and the compensator/intellicarb port is on the bottom. Here is a pic of the weird stock setup, throttle goes behind, up and around the back of the carb, choke it pushed by the linkage in the front.
View attachment 117046
Can an 034 muffler spacer be used here?
When using the 044 carb you will have to create new throttle and choke linkage.
Throttle linkage was easy. Used a stock 044 linkage, just cut it shorter on the trigger side and put a new 90 degree bend in it to insert into the trigger. I did need to grind away an area on the handle itself, behind the throttle lever on the carb to allow full movement. Choke linkage was not so easy. I ended up screwing a small eye bolt into the plastic position switch rod and making new linkage to attach to it from some really small RC car swiveling rod ends I got from the local hobby shop. They did need to be cut slightly shorter to fit. They are plastic so they are easy to work with. They are connected together by a very short piece of #4-40 threaded rod. (You could also use 3mm rod, the ends do not come internally threaded so you can use either size) If anyone needs any of the linkage it was Traxxas part # 2742 and comes 6 in a pack. The stock fuel line fit, I cut it slightly shorter. The brass fuel barb did need to be turned and angled down slightly and I also cut about 1/8” off the brass fuel barb to prevent the line from kinking. The 044 carb also has the impulse below the carb. luckily it lines up with a recess behind

Working on fitting the exhaust next. Going to need to make a 1/4” thick spacer to get the stock muffler to fit. View attachment 117049

Click to expand...

Can you use an OEM 034 muffler spacer?

Lightning Performance said:

Can you use an OEM 034 muffler spacer?

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Probably would work, might need to stack 2, I’m not sure how thick they are. But I don’t have any of those and I have a 1/4” thick sheet of aluminum here lying around. I’ll just cut it out using a bandsaw and a drill press