Have you figured out why the area in question is getting hot enough to melt? Exhaust leak? Muffler plugged? Residual heat that gets trapped where it shouldn't? Lack of proper air circulation around the engine? Is the engine tuned properly in the first place (too lean = too hot)?

In any case, the answer isn't going to be an "oversized" muffler, seeing as there is no such thing out there. Possible answers would include modifying the muffler to decrease backpressure (and retuning carb in response to the modified muffler, etc...), but this should be viewed as an improvement and shouldn't be viewed as a solution - your problem shouldn't be happening in the first place. So you need to figure out what's going on.

In any case, it might be worth having someone knowledgeable look at the saw, recognizing that whatever you saved on this saw will soon be spent getting it running *right* again. It is also a good lesson about why modern Poulan/Homelite/Craftsman/TroyBilt/McCulloch/etc. saws should be avoided - they are per se garbage and it is only through sheer luck that a decent one comes through their factory every once in a while. Had you spent your money on a good machine of reputable manufacture, you likely would not be having these problems.

I know this answer is coming late, but if your still around this may help you. Whats up with these Poulan 2900 saws is there is a spark arrester cover that goes on the bar cover side of the muffler. When the screen plugs up or the screws vibrate out, the cover falls off. Then the exhaust blows straight on the brake arm/bar cover and melts it.

You need to take a piece of light sheet metal and make a baffle to channel the exhaust away from the brake handle/bar cover. If your willing to do this it will solve the problem. I know because I have one. Echo's saws are the exact same way. Ive seen them with the factory baffle pointing the wrong direction and it just makes a mess out of everything.

Best wishes,
Bob.

computeruser, Your rant about the Poulan and related brands being garbage is unfounded. My experience with Poulan saws has been that they are quite good units and suffer from the same problems that most small engines suffer from. That being the use of old and/or contaminated fuel as well as other consumer induced problems. Even big name brand saws have similar problems under consumer use.

99% of the time, the key to whether a chainsaw or any other tool performs well is proper care and maintenance. I've repaired high dollar equipment that could be considered "garbage" just because the owners didn't follow the owners guide/preventive maintenance. I now own 7 Echo blowers, 2 of which are backpaks, 2 sears push leaf blower/shredders, i think 9 weedeaters, and somewhere around 12 lawnmowers. All at one time considered garbage by the previous owners. But, we poor folks need people to keep buying the "garbage" lol

nod702 and I thought I was the only one that pulled them from the trash and get 10 more years of use out of them. Polan hmmmm. I brought older model one at a garage sale last week for 5 bucks. The owner said it wouldn't run. The thing looked like new. Took me about 20 mins. to get it going. Other than getting it to suck fuel up (model didn'have a primer bulb) due to inactivity and sharpen the chain it ran like new.

Sounds to me like the exhaust may not be melting the chainbrake, but rather the clutch drum heating up and causing problems. I had a Poulan 2250 that was doing that, the bearings were so bad on the drum that they were just overheating like crazy. Easy fix, get a new sprocket drum, grease it up, put it on the saw.

lok at the muffler back plate- there should be a 90 degree bend that directs the exhaust forward

The 2900 Farm hand did not come with a chain brake

I have gone to Electric Chainsaws and Brands Have Not Mattered. I Find Care and User Experience Is A Big Factor X Experiences. I have Gas Saws that are almost History due to Working Firewood left by Tree Trimmers....

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