Alaskan Sawmill Rails Guide (5 Pro Tips For Long Timbers)

I still remember the first time I tried to mill a log into lumber. It was a humbling experience. I envisioned perfectly squared boards, but instead, I ended up with a wavy, uneven mess. It was then I realized the importance of a good Alaskan sawmill setup, especially the rails. Over the years, I’ve learned a lot about getting the most out of these tools, and I’m excited to share my pro tips for milling long timbers. These lessons will help you avoid the pitfalls I encountered and produce high-quality lumber, whether you’re a seasoned woodworker or just starting. So, let’s dive in!

Alaskan Sawmill Rails Guide: 5 Pro Tips for Long Timbers

Using an Alaskan sawmill is a fantastic way to turn logs into usable lumber right on site. It’s economical, portable, and gives you control over the entire milling process. However, milling long timbers presents unique challenges. Warping, inaccurate cuts, and safety concerns can quickly derail your project. Having spent countless hours milling everything from small cedar logs to massive oak trees, I’ve fine-tuned my approach to using Alaskan sawmill rails. My aim is to share practical advice that will enhance your milling efficiency and improve the quality of your lumber.

1. Choosing the Right Rails

The foundation of accurate milling lies in selecting the right rails. Don’t skimp here – your rails are the backbone of the entire operation.

Understanding Rail Materials

Aluminum and steel are the most common materials for sawmill rails.

Aluminum: Lighter and easier to handle, aluminum rails are great for portability. However, they can flex more than steel, especially with heavier cuts or longer spans. I’ve used aluminum rails for milling softer woods like pine and cedar, and they’ve performed admirably. Just be sure to check for any bending or warping after each use.
Steel: Steel rails are heavier and more robust, providing superior rigidity. This is crucial for milling long, heavy timbers where precision is paramount. I prefer steel when milling hardwoods like oak or maple because they minimize vibration and deflection.

Rail Length and Extension Considerations

Your rail length should always exceed the length of the longest timber you plan to mill. For example, if you’re milling a 20-foot log, your rails should be at least 22 feet long to allow for end cuts and adjustments.

Extending Rails: If you need to mill even longer timbers, you can extend your rails using connectors. Ensure the connectors are robust and precisely aligned to maintain accuracy. I’ve used extension kits that bolt together, providing a seamless and stable platform.
Overlap: When extending rails, overlap them by at least 12 inches and secure them with multiple bolts. This minimizes any potential weak points and ensures a smooth, continuous surface for your mill to ride on.

Rail Straightness and Rigidity

The straighter and more rigid your rails, the more accurate your cuts will be.

Checking Straightness: Before each milling session, I use a long, straight edge (a level or another straight rail) to check the straightness of my rails. Any deviations can cause uneven cuts.
Reinforcing Rails: For long spans, consider adding supports beneath the rails to prevent sagging. I often use wooden blocks or adjustable stands spaced every 4-6 feet.

Takeaway: Invest in high-quality rails made of the appropriate material for your typical timber size and wood type. Always check for straightness and reinforce as needed.

2. Setting Up Your Rails for Accuracy

Proper setup is critical. Even the best rails won’t produce accurate cuts if they’re not correctly aligned and leveled.

Preparing the Milling Site

Choose a level and stable area for your milling site. Clear away any debris, rocks, or vegetation that could interfere with the rails.

Ground Leveling: Use a shovel and level to create a flat surface. For uneven terrain, consider building a temporary platform using lumber or plywood.
Drainage: Ensure proper drainage to prevent water from pooling around your milling site. This can cause the wood to warp and make the area slippery.

Aligning and Leveling the Rails

This is where patience and precision are key.

Initial Alignment: Place the rails parallel to each other on the prepared surface. Use a measuring tape to ensure they are the same distance apart along their entire length. I typically aim for a spacing that matches the width of my chainsaw bar plus a few extra inches for clearance.
Leveling: Use a long level (at least 4 feet) to check the level of each rail. Shim the rails with wooden shims or small blocks until they are perfectly level. Check the level at multiple points along the length of each rail.
Cross-Checking: Once the rails are level individually, use a straight edge or a laser level to ensure they are level relative to each other. This will ensure that your cuts are consistent and parallel.
Securing the Rails: Once the rails are aligned and leveled, secure them in place. You can use stakes driven into the ground, or you can attach them to a temporary platform. This prevents them from shifting during the milling process.

Ensuring Parallelism

Parallel rails are essential for consistent board thickness.

Measuring at Intervals: Measure the distance between the rails at several points along their length. Any discrepancies indicate a lack of parallelism.
Adjusting as Needed: Use shims or adjustments on your rail supports to correct any parallelism issues. Re-measure after each adjustment.

Takeaway: A meticulously leveled and aligned rail system is the cornerstone of accurate milling. Take your time and double-check your work.

3. Optimizing Chainsaw and Mill Setup

The chainsaw and mill need to be in top condition and properly adjusted to get the best results.

Chainsaw Selection and Maintenance

A powerful chainsaw with a long bar is essential for milling.

Engine Size: I recommend a chainsaw with at least 70cc engine for milling hardwoods. For softer woods, a 60cc engine may suffice.
Bar Length: Choose a bar length that is slightly longer than the diameter of the largest log you plan to mill. I typically use a 36-inch bar for most of my milling projects.
Chain Type: Use a ripping chain specifically designed for milling. These chains have a different tooth geometry than standard chains, allowing them to cut along the grain more efficiently.
Chain Sharpness: A sharp chain is crucial for smooth and accurate cuts. Sharpen your chain frequently, especially when milling hardwoods. I usually sharpen my chain after every few cuts.
Chain Tension: Maintain proper chain tension to prevent the chain from derailing or binding. Check the tension regularly and adjust as needed.
Air Filter: Keep the air filter clean to ensure proper engine performance. A dirty air filter can reduce power and cause the engine to overheat.
Fuel Mixture: Use the correct fuel mixture as specified by the chainsaw manufacturer. Incorrect fuel mixtures can damage the engine.

Mill Adjustments and Calibration

Ensure your Alaskan sawmill is properly adjusted and calibrated to your chainsaw.

Attachment Security: Verify that the mill is securely attached to the chainsaw bar. Loose attachments can cause vibrations and inaccurate cuts.
Depth Adjustment: Calibrate the depth adjustment on the mill to achieve the desired board thickness. Use a ruler or calipers to measure the thickness of the first few boards and adjust as needed.
Oil Flow: Ensure that the oiler on your chainsaw is functioning properly. Adequate oil flow is essential to prevent the chain from overheating and binding. I often manually oil the chain as well, especially when milling long timbers.
Leveling the Mill: Use a small level to ensure that the mill is level relative to the chainsaw bar. This will help prevent the mill from tipping or tilting during the cut.

Chain Oiling Techniques

Proper chain lubrication is vital for smooth cutting and extending the life of your chain and bar.

High-Quality Bar Oil: Use a high-quality bar and chain oil specifically designed for chainsaw use. Avoid using motor oil or other substitutes, as they may not provide adequate lubrication.
Manual Oiling: In addition to the automatic oiler on your chainsaw, manually oil the chain and bar frequently, especially when milling long timbers or hardwoods. This will help prevent overheating and binding.
Oiling Frequency: I typically oil the chain every few feet when milling hardwoods and every 5-6 feet when milling softwoods.
Checking Oil Flow: Regularly check the oil flow from the chainsaw’s oiler. If the oiler is not functioning properly, clean or replace it.

Takeaway: A well-maintained chainsaw and a properly calibrated mill are essential for efficient and accurate milling. Pay attention to detail and make adjustments as needed.

4. Milling Techniques for Long Timbers

Milling long timbers requires a different approach than milling shorter logs. Patience, steady hands, and attention to detail are crucial.

Making the First Cut

The first cut is the most critical, as it establishes the reference surface for all subsequent cuts.

Slow and Steady: Take your time and make the first cut slowly and steadily. Avoid forcing the chainsaw, as this can cause the bar to bend or the chain to bind.
Consistent Speed: Maintain a consistent speed throughout the cut. Varying the speed can result in uneven board thickness.
Monitoring the Cut: Constantly monitor the cut to ensure that the mill is tracking straight and true. If you notice any deviations, stop the cut and make adjustments.
Using a Guide Board: Some millers use a guide board attached to the log to help guide the first cut. This can be especially helpful for milling logs with irregular shapes.

Subsequent Cuts

Once the first cut is complete, subsequent cuts are easier but still require attention to detail.

Maintaining Pressure: Apply consistent pressure to the mill as you move it along the rails. Avoid pushing too hard, as this can cause the chain to bind.
Overlapping Cuts: For very long timbers, you may need to make overlapping cuts. Start the cut at one end of the log and stop before reaching the other end. Then, start the next cut at the other end of the log and overlap the first cut by a few inches.
Removing Waste: Regularly remove waste material from the cut to prevent it from binding the chain. I often use a small wedge or pry bar to create space for the chain.

Dealing with Log Stress

Logs can contain internal stresses that can cause them to warp or crack during milling.

Relieving Stress: To relieve stress, make a series of shallow cuts along the length of the log before making the final cut. This will allow the log to expand or contract without warping.
Cutting Strategy: Consider the grain pattern of the log when planning your cuts. Cutting parallel to the grain can help minimize warping.
Sealing Ends: Seal the ends of the freshly milled lumber with a moisture sealant to prevent end-checking (cracking).

Managing Vibration

Vibration can be a significant issue when milling long timbers, especially with longer rails.

Secure Rail Supports: Ensure your rail supports are solid and well-anchored to minimize vibration.
Dampening Materials: Place rubber pads or other dampening materials between the rails and the supports to absorb vibration.
Slower Cutting Speed: Reduce your cutting speed to minimize vibration.
Inspect Mill Regularly: Routinely inspect the mill for loose bolts or worn parts, as these can contribute to vibration.

Takeaway: Milling long timbers requires patience and precision. Take your time, monitor the cut closely, and adjust your technique as needed.

5. Safety First

Safety should always be your top priority when operating an Alaskan sawmill.

Personal Protective Equipment (PPE)

Always wear appropriate PPE when milling lumber.

Eye Protection: Wear safety glasses or a face shield to protect your eyes from flying debris.
Hearing Protection: Wear earplugs or earmuffs to protect your hearing from the loud noise of the chainsaw.
Hand Protection: Wear gloves to protect your hands from cuts and abrasions.
Foot Protection: Wear steel-toed boots to protect your feet from falling logs and sharp objects.
Leg Protection: Wear chainsaw chaps to protect your legs from accidental chainsaw contact.

Safe Chainsaw Handling

Follow these guidelines for safe chainsaw handling.

Read the Manual: Familiarize yourself with the chainsaw manufacturer’s instructions and safety guidelines.
Proper Stance: Maintain a stable stance with your feet shoulder-width apart.
Secure Grip: Grip the chainsaw firmly with both hands.
Avoid Overreaching: Avoid overreaching or cutting above shoulder height.
Clear Work Area: Keep the work area clear of obstacles and bystanders.
Never Cut Alone: Always have someone nearby in case of an emergency.
Inspect Equipment: Inspect the chainsaw and mill before each use to ensure they are in good working condition.
Safe Fueling: Fuel the chainsaw in a well-ventilated area away from sparks or flames.
Chain Brake: Engage the chain brake when not actively cutting.

Preventing Kickback

Kickback is a dangerous phenomenon that can occur when the tip of the chainsaw bar contacts a solid object.

Avoid Tip Contact: Be aware of the location of the tip of the bar and avoid contacting it with solid objects.
Proper Technique: Use proper cutting techniques to minimize the risk of kickback.
Chain Brake: Ensure that the chain brake is functioning properly and use it as needed.
Reduced-Kickback Chain: Consider using a reduced-kickback chain.

Emergency Preparedness

Be prepared for emergencies.

First Aid Kit: Keep a well-stocked first aid kit on site.
Communication: Have a way to communicate with emergency services.
Emergency Plan: Develop an emergency plan in case of an accident.
Know Your Limits: Don’t attempt to mill logs that are too large or too difficult for your skill level.

Takeaway: Safety is paramount. Always wear appropriate PPE, follow safe chainsaw handling practices, and be prepared for emergencies.

These five pro tips should give you a solid foundation for milling long timbers with an Alaskan sawmill. Remember, patience and attention to detail are key to producing high-quality lumber. By following these guidelines, you can minimize waste, maximize efficiency, and stay safe while enjoying the rewarding experience of milling your own lumber. Now, get out there and start milling! But always remember safety first.

Alaskan Sawmill Rails Guide (5 Pro Tips for Long Timbers)