Process question/chainsaw handle repair

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Thank you for your time. Last summer, being a good neighbor, I felled a few trees in my neighbor's backyard.  In the process of cutting the trunk down to size, I had a log get away from me and roll against my saw breaking the handle in the process.Saw in questions is a Deere 65SV made by Echo; replacement handle is $75+.  Before having to spend that kind of $$$ and go through the pain of making colors match, I would like to attempt to fix this by welding it back together.Question:  What process could I use to join th parts together?  Handle looks like it is some type of cast metal; please see pics for better idea of what I am looking at.Any and all comments/advice is greatly appreciated.  In search of my next cold one, NearBeer Attached Images
Reply:If it is aluminum GTAW is the best choice. You could use GMAW but that thin and light of material will present issues for the novice.
Reply:Unless it is magnesium, and not aluminum.Lots of chainsaws use magnesium to save on weight.If you put a little white vinegar on the exposed metal, it will fizz up if it is magnesium, and do nothing on aluminum.If it is magnesium, it may not be worth repairing, because magnesium filler rod can be quite costly (and it is hard to buy in small batches), and it is much more difficult to weld.Either way, GTAW is your best option.
Reply:I'd bet money it's magnesium....Mike
Reply:bet it s mag alsomayb a strap an some small bolts [strap both sides--paint yellowidealarc 250/250 ac-dc tigidealarc 250/250 ac-dc tig #2 used for sticklincoln sp100hh125dual arbor grinder polisher30 yrs of hand tools52 pitch blocks 6p-26prake gauge -pitch gaugeG&D prop repair 918-207-6938Hulbert,okla 74441
Reply:Originally Posted by prop-doctormayb a strap an some small bolts [strap both sides--paint yellow
Reply:If it is magnesium, you could try asking at your local saw repair place if they have any broken castings from the same maker--you want to get the same alloy--and cut some small pieces from that to use as filler. Be sure to use parts not saturated with oil, and clean down to bare metal, preferably by filing.  Remember that Mag alloys are often "hot short" so you need to support things well.They also burn well, so require care and understanding to prevent problems.Almost forgot to ask; what model and age is the saw? From the picture, I'd guess it's a bit older..Last edited by Oldiron2; 12-16-2010 at 04:04 PM.
Reply:Deere 65SV was bought back in '85 and has run like a champ since then; 20" bar.  Made in Japan by the same company that made Echoes from the same era.  Unlike the ChiCom pieces of s%^t that are on the shelves of the big box stores.
Reply:Mike et al:Poured a capful on the exposed areas once I came home from work...Magnesium it is...Guess I am plopping down the $ for a replacement part in Echo orange! Thanks for the trick on determing if it is Mg or Al.
Reply:I think  I've got a couple of 12" pieces of mag rod, you're welcome to them if you want....Mike
Reply:Mr.Mikey:Let me ask around at work if someone can TIG it for me; if they can, I'll hit you up for the rods.  Please accept my thanks for offering./R,NearBeer
Reply:I have used the low temp ally brazing rods for a similar repair to a big wolf drilling machine, and they worked absolutely great, Machine still going strong 3 years later,Lincoln SP-170 MigHypertherm powermax 45Lorch T220 AC/DC TigButters FM 215 synergic MigKemppi 180 adaptive mig RULES ARE FOR THE OBEDIENCE OF FOOLS AND THE  GUIDANCE OF WISE MEN.
Reply:Originally Posted by gordon stephensonI have used the low temp ally brazing rods for a similar repair to a big wolf drilling machine, and they worked absolutely great, Machine still going strong 3 years later,