Bow Bar Chainsaw For Sale: Poulan 4000 Review (Old Saw Revival)

Let’s dive into the world of chainsaws, specifically the Poulan 4000 with a bow bar, and its potential revival for wood processing and firewood preparation. The user’s intent – “Bow Bar Chainsaw for Sale: Poulan 4000 Review (Old Saw Revival)” – clearly indicates an interest in purchasing a used Poulan 4000 chainsaw, likely equipped with a bow bar, and seeking information about its capabilities, potential, and suitability for modern use, especially in the context of reviving an older piece of equipment. My experience in wood processing has taught me that understanding the nuances of vintage saws like the Poulan 4000 is crucial before committing to a purchase. It’s not just about the price; it’s about the saw’s functionality, safety, and overall value proposition.

The Allure of the Bow Bar Chainsaw: Reviving a Poulan 4000

The bow bar chainsaw, once a common sight in logging operations, has largely been replaced by conventional bar chainsaws due to safety concerns and advancements in chainsaw technology. However, a renewed interest exists among hobbyists and small-scale woodworkers in reviving these vintage saws. The Poulan 4000, a workhorse of its time, is a prime candidate for such a revival. I remember my grandfather used one for years, and its distinctive sound still echoes in my mind when I’m processing timber.

What is a Bow Bar Chainsaw?

A bow bar chainsaw features a curved, bow-shaped cutting attachment instead of a traditional straight bar. The chain runs around the perimeter of this bow.

Purpose: Primarily designed for bucking (cutting logs into shorter lengths), especially pulpwood.
Advantages (Historically): Faster plunge cuts and the ability to cut through small-diameter logs quickly without pinching.
Disadvantages: Significantly higher risk of kickback compared to straight bar chainsaws. Reduced precision in cuts. More difficult to fell trees safely.

Why Revive an Old Poulan 4000?

The appeal lies in several factors:

Nostalgia: For some, it’s a sentimental connection to a bygone era of logging.
Cost: Used Poulan 4000s can be acquired for a fraction of the price of a new chainsaw.
Simplicity: Older saws often have simpler mechanics, making them easier to repair and maintain (in theory).
Potential Power: The Poulan 4000 was known for its robust engine, offering significant cutting power.

However, it’s crucial to approach this revival with a clear understanding of the challenges involved.

Assessing the Poulan 4000: A Step-by-Step Guide

Before even considering a purchase, a thorough assessment is critical. My own experience with restoring vintage equipment has taught me that due diligence upfront saves significant headaches (and money) later.

Step 1: Initial Inspection – The Visual Check

Overall Condition: Look for signs of excessive wear and tear, rust, or damage to the engine housing, fuel tank, and handles.
Bow Bar Integrity: Inspect the bow bar for cracks, bends, or welding repairs. A damaged bow bar is a major safety hazard.
Chain Condition: Check the chain for sharpness, damage, and proper tension. A dull or damaged chain is not only inefficient but also increases the risk of kickback.
Safety Features: Older chainsaws often lack modern safety features like chain brakes. Verify if the Poulan 4000 has a functional chain brake (if equipped) and ensure that the throttle lock and kill switch are working correctly.

My Insight: Don’t be afraid to walk away from a saw that looks heavily abused. The cost of repairing a severely damaged saw can easily exceed the price of a newer, safer model.

Step 2: Engine Examination – The Heart of the Saw

Compression Test: This is perhaps the most crucial test. A healthy engine should have good compression. Use a compression tester (available at most auto parts stores) to measure the compression. A reading below 90 PSI indicates significant engine wear.
Spark Plug Inspection: Remove the spark plug and examine its condition. A fouled or oily spark plug suggests engine problems. The color of the spark plug can also provide clues about the engine’s running condition. A light tan color is ideal.
Fuel System Check: Inspect the fuel lines for cracks or leaks. Check the fuel filter and fuel tank for debris. A clogged fuel system is a common issue in older chainsaws.
Carburetor Examination: The carburetor is responsible for mixing fuel and air. Look for signs of damage or corrosion. The carburetor may need to be cleaned or rebuilt.

Data Point: A well-maintained Poulan 4000 should easily achieve a compression reading of 120 PSI or higher.

Step 3: Starting and Running – The Sound of Truth

Starting Procedure: Follow the manufacturer’s recommended starting procedure. If the saw is difficult to start, it could indicate a problem with the fuel system, ignition system, or engine compression.
Idle Speed: Once started, the saw should idle smoothly without stalling. An erratic idle speed suggests a carburetor issue.
Throttle Response: The engine should respond quickly and smoothly when the throttle is engaged. Hesitation or bogging down indicates a problem with the fuel system or carburetor.
Smoke Output: Excessive smoke can indicate a problem with the fuel mixture or engine wear. Blue smoke suggests burning oil, while black smoke suggests a rich fuel mixture.
Chain Lubrication: Verify that the chain is being properly lubricated. Insufficient chain lubrication can lead to premature wear and damage to the bar and chain.

Personal Story: I once bought a vintage chainsaw that started easily but stalled frequently under load. After hours of troubleshooting, I discovered a tiny crack in the fuel line that was causing air to leak into the fuel system. Replacing the fuel line solved the problem.

Step 4: Bar and Chain Assessment – The Cutting Edge

Bar Condition: Inspect the bar for wear, damage, and proper alignment. The bar should be straight and the rails should be in good condition.
Chain Sharpness: A sharp chain is essential for efficient and safe cutting. Sharpen the chain using a chainsaw file or a chain grinder.
Chain Tension: Adjust the chain tension according to the manufacturer’s recommendations. The chain should be snug on the bar but should still be able to be pulled around by hand.
Chain Type: Ensure that the chain is the correct type and size for the chainsaw. Using the wrong chain can damage the saw and create a safety hazard.

Tool Specification: A chainsaw file with a diameter of 5/32″ is typically used for sharpening the chain on a Poulan 4000.

Step 5: Safety Feature Verification – Paramount Importance

Chain Brake: Test the chain brake to ensure that it is functioning properly. The chain brake should stop the chain immediately when engaged.
Throttle Lock: Verify that the throttle lock prevents the throttle from being engaged accidentally.
Kill Switch: Ensure that the kill switch is working correctly and can quickly shut off the engine in an emergency.
Hand Guards: Check for the presence and condition of hand guards.

Original Insight: Never operate a chainsaw without functional safety features. The risk of injury is simply too high.

Restoring the Poulan 4000: A Hands-On Approach

If the Poulan 4000 passes the initial assessment, the next step is restoration. This involves cleaning, repairing, and replacing worn parts.

Step 1: Cleaning and Disassembly

Thorough Cleaning: Clean the entire chainsaw with a degreaser and brush. Remove any dirt, grease, and debris.
Careful Disassembly: Disassemble the chainsaw carefully, taking note of the location of each part. Take pictures or videos to help with reassembly.
Parts Inspection: Inspect each part for wear, damage, or corrosion. Replace any worn or damaged parts.

My Experience: I always use a parts tray and label each compartment to keep track of the various components during disassembly. This prevents confusion and makes reassembly much easier.

Step 2: Engine Rebuild (If Necessary)

Cylinder and Piston Inspection: Inspect the cylinder and piston for wear, scoring, or damage. If necessary, replace the cylinder and piston.
Crankshaft and Bearings: Check the crankshaft and bearings for wear or damage. Replace the crankshaft and bearings if necessary.
Seals and Gaskets: Replace all seals and gaskets to prevent leaks.

Technical Detail: When replacing the piston, ensure that the piston ring end gap is within the manufacturer’s specifications.

Step 3: Fuel System Overhaul

Carburetor Cleaning and Rebuild: Clean the carburetor thoroughly with carburetor cleaner. Replace any worn or damaged parts, such as the diaphragm and needle valve. A carburetor rebuild kit is often the easiest solution.
Fuel Line Replacement: Replace all fuel lines with new fuel lines designed for gasoline.
Fuel Filter Replacement: Replace the fuel filter with a new filter.
Fuel Tank Cleaning: Clean the fuel tank to remove any debris.

Case Study: I once spent hours trying to diagnose a chainsaw that wouldn’t run properly. After replacing the fuel lines, fuel filter, and spark plug, I finally discovered that the fuel tank was full of varnish from old fuel. Cleaning the fuel tank solved the problem.

Step 4: Ignition System Check

Spark Plug Replacement: Replace the spark plug with a new spark plug of the correct type.
Ignition Coil Inspection: Inspect the ignition coil for cracks or damage. Test the ignition coil with a multimeter to ensure that it is producing sufficient voltage.
Points and Condenser (If Applicable): If the Poulan 4000 has points and a condenser, inspect them for wear or damage. Replace the points and condenser if necessary.

Cost Estimate: A new spark plug typically costs around $5, while a new ignition coil can cost between $20 and $50.

Step 5: Reassembly and Testing

Careful Reassembly: Reassemble the chainsaw carefully, following the disassembly notes and pictures.
Initial Testing: Start the chainsaw and let it idle for a few minutes. Check for leaks or unusual noises.
Load Testing: Put the chainsaw under load by cutting a log. Verify that the engine is running smoothly and that the chain is being properly lubricated.
Final Adjustments: Make any necessary adjustments to the carburetor and chain tension.

Strategic Advantage: Spending the time to properly tune the carburetor will result in a chainsaw that runs more efficiently, produces less emissions, and lasts longer.

Bow Bar Chainsaw Safety: A Non-Negotiable Aspect

Operating a bow bar chainsaw requires a heightened awareness of safety. The risk of kickback is significantly higher compared to conventional chainsaws.

Understanding Kickback

Kickback occurs when the chain on the upper quadrant of the bow bar contacts a solid object. This can cause the chainsaw to suddenly and violently kick back towards the operator.

Causes: Contact with knots, embedded objects, or the sides of the cut.
Prevention:
- Avoid using the upper quadrant of the bow bar.
- Maintain a firm grip on the chainsaw with both hands.
- Keep your body out of the path of the chainsaw.
- Be aware of your surroundings and avoid cutting near obstacles.
- Use a low-kickback chain.

Essential Safety Gear

Helmet with Face Shield: Protects your head and face from flying debris.
Eye Protection: Safety glasses or goggles provide additional eye protection.
Hearing Protection: Earplugs or earmuffs protect your hearing from the loud noise of the chainsaw.
Gloves: Protect your hands from cuts and abrasions.
Chainsaw Chaps or Pants: Protect your legs from chainsaw cuts.
Steel-Toed Boots: Protect your feet from falling logs and chainsaw cuts.

Data Point: Wearing chainsaw chaps can significantly reduce the severity of leg injuries in the event of a chainsaw accident.

Safe Operating Practices

Read the Owner’s Manual: Familiarize yourself with the chainsaw’s operating instructions and safety precautions.
Inspect the Chainsaw Before Each Use: Check for loose parts, damage, and proper lubrication.
Start the Chainsaw on the Ground: Never drop-start a chainsaw.
Maintain a Safe Distance: Keep bystanders at least 20 feet away from the cutting area.
Never Cut Above Shoulder Height: This increases the risk of losing control of the chainsaw.
Take Breaks: Avoid fatigue, which can lead to accidents.
Never Operate a Chainsaw Under the Influence of Drugs or Alcohol.

Personal Anecdote: I once witnessed a near-miss accident when a fellow woodworker attempted to cut a log above shoulder height with a bow bar chainsaw. The chainsaw kicked back, narrowly missing his face. This incident reinforced the importance of following safe operating practices.

The Poulan 4000 with Bow Bar: Applications and Limitations

While the Poulan 4000 with a bow bar can be a useful tool, it’s important to understand its limitations and appropriate applications.

Suitable Applications

Bucking Pulpwood: Historically, this was the primary application for bow bar chainsaws.
Cutting Small-Diameter Logs: The bow bar can be effective for quickly cutting through small logs without pinching.
Niche Woodworking Projects: For certain specialized woodworking tasks where a plunge cut is required.

Limitations

Felling Trees: Bow bar chainsaws are not suitable for felling trees due to the lack of precision and increased risk of kickback.
Cutting Large-Diameter Logs: The limited cutting depth of the bow bar makes it difficult to cut through large logs.
Precision Cutting: The bow bar is not ideal for precision cutting tasks.
Safety Concerns: The increased risk of kickback makes bow bar chainsaws less safe than conventional chainsaws.

Original Insight: For most wood processing and firewood preparation tasks, a modern chainsaw with a standard bar is a safer and more versatile option than a Poulan 4000 with a bow bar.

Modern Alternatives to the Bow Bar Chainsaw

Advancements in chainsaw technology have largely rendered the bow bar chainsaw obsolete. Modern chainsaws offer improved safety features, performance, and versatility.

Conventional Chainsaws

Safety Features: Modern chainsaws are equipped with chain brakes, anti-vibration systems, and low-kickback chains.
Performance: Modern chainsaws offer improved power, fuel efficiency, and cutting speed.
Versatility: Conventional chainsaws can be used for a wide range of tasks, including felling trees, bucking logs, and limbing branches.

Electric Chainsaws

Convenience: Electric chainsaws are lightweight, quiet, and easy to start.
Environmental Friendliness: Electric chainsaws produce no emissions.
Limitations: Electric chainsaws typically have less power than gasoline-powered chainsaws and are not suitable for heavy-duty tasks.

Battery-Powered Chainsaws

Portability: Battery-powered chainsaws are portable and can be used in remote locations.
Convenience: Battery-powered chainsaws are easy to start and require minimal maintenance.
Limitations: Battery-powered chainsaws typically have a limited run time and may not be suitable for heavy-duty tasks.

Tool Specification: A Stihl MS 271 Farm Boss is a popular and reliable conventional chainsaw that is suitable for a wide range of wood processing and firewood preparation tasks.

Firewood Preparation: A Practical Application

If you decide to use the Poulan 4000 (after careful restoration and safety checks) for firewood preparation, here’s a breakdown of the process:

Step 1: Sourcing Firewood

Green Wood vs. Seasoned Wood: Green wood is freshly cut wood that has a high moisture content. Seasoned wood has been dried for several months and has a lower moisture content. Seasoned wood burns more efficiently and produces less smoke.
Wood Species: Different wood species have different burning properties. Hardwoods, such as oak and maple, burn longer and produce more heat than softwoods, such as pine and fir.
Sustainable Sourcing: Obtain firewood from sustainable sources, such as dead trees or responsibly harvested timber.

Definition: Green wood typically has a moisture content of 50% or higher, while seasoned wood has a moisture content of 20% or lower.

Step 2: Bucking Logs into Firewood Lengths

Determine Firewood Length: The ideal firewood length depends on the size of your fireplace or wood stove. A common firewood length is 16 inches.
Use a Measuring Tool: Use a measuring tape or a firewood measuring stick to ensure that the firewood is cut to the correct length.
Cut the Logs: Use the Poulan 4000 (with extreme caution) or a conventional chainsaw to cut the logs into firewood lengths.

Measurement: A firewood measuring stick can be easily made from a piece of wood marked with the desired firewood length.

Step 3: Splitting Firewood

Axe vs. Log Splitter: An axe is a traditional tool for splitting firewood. A log splitter is a hydraulic machine that splits firewood more quickly and easily.
Safety Precautions: Wear safety glasses and gloves when splitting firewood.
Splitting Technique: Position the log on a solid surface. Place the axe or log splitter wedge on the log and strike it with a hammer or use the hydraulic ram to split the log.

Benefit: Using a hydraulic log splitter can significantly reduce the physical strain and time required to split firewood.

Step 4: Stacking Firewood

Proper Stacking: Stack the firewood in a way that allows for good air circulation. This will help the firewood to dry more quickly.
Elevated Stacking: Stack the firewood on pallets or other elevated surfaces to prevent it from contacting the ground.
Covering Firewood: Cover the top of the firewood stack with a tarp to protect it from rain and snow.

Case Study: I once stacked firewood directly on the ground, and it rotted before it had a chance to dry. Since then, I always stack firewood on pallets.

Step 5: Seasoning Firewood

Drying Time: Firewood typically needs to be seasoned for at least six months to a year before it is ready to burn.
Moisture Content Measurement: Use a moisture meter to measure the moisture content of the firewood. Firewood should have a moisture content of 20% or lower before it is burned.
Storage Location: Store the firewood in a well-ventilated location that is protected from rain and snow.

Timing Estimate: The drying time for firewood depends on the wood species, the size of the firewood, and the climate.

Final Thoughts and Recommendations

Reviving a Poulan 4000 with a bow bar can be a rewarding project for those with a passion for vintage equipment. However, it’s crucial to approach this project with a clear understanding of the risks and limitations involved. Prioritize safety above all else.

Thorough Assessment: Conduct a thorough assessment of the Poulan 4000 before making a purchase.
Safety First: Prioritize safety by wearing appropriate safety gear and following safe operating practices.
Consider Modern Alternatives: Explore modern chainsaw options that offer improved safety, performance, and versatility.
Proper Firewood Preparation: Follow proper firewood preparation techniques to ensure that you are burning seasoned wood safely and efficiently.

Next Steps:

Research local sources for used Poulan 4000 chainsaws.
Obtain the necessary tools and equipment for restoring the chainsaw.
Enroll in a chainsaw safety course to learn safe operating practices.
Start small and gradually work your way up to more challenging wood processing tasks.

By following these guidelines, you can make an informed decision about whether to revive a Poulan 4000 with a bow bar and safely enjoy the benefits of wood processing and firewood preparation. Always remember safety is paramount.