Went with the JB Weld Plastic Bonder. It's ugly but has held together in idle and full throttle tests. Haven't had a chance to test in the field yet. Lesson learned: Pay very close attention when tightening this cover. I'm usually not one to over tighten things. Did so with this without even trying to.
Just guessing here but I think you tightened the cover with the little bar adjustment stub not in the hole of the bar. If so you won’t want to do that again lol. As long as the steel plates are still flat you may get away with this fix. If the two steel surfaces are no longer flat with each other you may want to get a replacement. Uneven surfaces could work at pulling out one of the bar studs and that’s even more fun to fix. Ask me how I know
Same thought I had. If the adjuster nub in in the hole and the cover flat against the bar, over tightening can't break it like that. Ive gotten a couple used saws broken like that and they had witness marks from the adjuster nub digging into the bar next to the hole.
jo191145 Eggshooterist I'm sure you're right. I remember having trouble getting it lined up and thought I had gotten it. I was surprised to hear it crack while tightening it. Got a chance to put it to work yesterday and it worked great. It's unfortunate that I didn't notice until I got home that the nut had backed off. New cover and some replacement cover nuts on order this morning.
Diagnosis confirmed. Cracked the old one again doing the same thing. I'm blaming my old eyes and newbieness. Had the bar adjustment stub lined up with the oil hole, not the hole for the stub. Thankfully had the new one on hand. Lesson learned. Field tested last week on red oak and poplar. All good now. Thanks to all for the help and advice! Even had a field buddy looking on.