Chainsaw Bar Rail Closer Fix (Pro Tips for Smooth Wood Cutting)

In recent years, I’ve observed a fascinating trend within the wood processing industry – a growing emphasis on tool maintenance and precision cutting. This isn’t just about efficiency; it’s about maximizing yield, minimizing waste, and, crucially, enhancing safety. More and more, people are realizing that a well-maintained chainsaw, particularly one with a properly aligned bar, is paramount for smooth, accurate, and safe wood cutting. This guide is dedicated to addressing a specific, yet critical aspect of chainsaw maintenance: fixing a closed chainsaw bar rail.

Chainsaw Bar Rail Closer Fix: Pro Tips for Smooth Wood Cutting

As someone who has spent countless hours in the woods, from felling trees for my own firewood to assisting in larger logging operations, I’ve learned firsthand the importance of a chainsaw that performs flawlessly. A common problem I’ve frequently encountered, and one that can significantly impact cutting performance and safety, is a closed chainsaw bar rail. This occurs when the rails on the chainsaw bar are pinched together, restricting the chain’s movement and leading to rough cuts, increased wear, and potentially dangerous kickback. I’m sharing my experiences and insights on diagnosing, correcting, and preventing this issue, ensuring your chainsaw operates at its peak.

Understanding Chainsaw Bar Rail Closure

What Causes Bar Rail Closure?

Before diving into the solutions, it’s important to understand the causes of closed bar rails. In my experience, several factors contribute:

• Overheating: Prolonged use, especially when cutting dense hardwoods, can cause the bar to overheat and warp. The heat expands the metal, and when it cools, the rails can contract inward. I’ve seen this happen most often on hot summer days when pushing the saw too hard.
• Improper Chain Tension: Running a chain too tight puts excessive stress on the bar, contributing to rail closure. Conversely, a chain that is too loose can cause the chain to slap against the bar, deforming the rails over time. I always make sure to adjust the chain tension after the first few cuts with a new chain.
• Lack of Lubrication: Insufficient oiling leads to increased friction and heat, which, as mentioned above, can warp the bar. A dry bar is a recipe for disaster. I once neglected to check the oil level on a particularly long day of cutting, and the resulting damage to the bar was a costly lesson.
• Impact Damage: Hitting rocks, metal objects, or even knots in the wood can cause the bar rails to bend inward. I recall a time when I accidentally struck a hidden fence post while clearing brush, resulting in a noticeable dent in the bar and subsequent rail closure.
• Improper Storage: Storing a chainsaw with the bar resting against a hard surface, especially in a warm environment, can also contribute to rail closure over time. I always store my chainsaws horizontally, with the bar supported to prevent any bending or warping.

Identifying a Closed Rail

Recognizing the signs of a closed bar rail is crucial for preventing further damage and ensuring safe operation. Here are some telltale indicators:

• Difficulty Installing or Removing the Chain: If the chain feels unusually tight or difficult to slide onto the bar, it’s a strong indication that the rails are closing.
• Chain Binding: The chain may bind or stall during cutting, especially when entering the cut. This is a common symptom of restricted chain movement.
• Uneven Cutting: The saw may cut crookedly or produce rough, splintered edges. I’ve often noticed this when trying to make precise cuts for milling lumber.
• Excessive Wear on the Chain and Bar: A closed rail increases friction, leading to premature wear on both the chain and the bar. I always inspect my chains regularly for signs of excessive wear, such as rounded cutters or worn tie straps.
• Overheating of the Bar: The bar may become excessively hot during use, even with proper lubrication. This is a sign that the chain is struggling to move freely.
• Visual Inspection: Carefully examine the bar rails for any signs of pinching or inward bending. A straightedge can be helpful for identifying deviations.

Data Points and Statistics

• Bar Wear Rate: Studies show that a chainsaw bar with closed rails can experience up to a 50% increase in wear rate compared to a properly aligned bar. This translates to shorter bar life and increased replacement costs.
• Chain Speed Reduction: Closed rails can reduce chain speed by as much as 20%, leading to slower cutting and increased fuel consumption.
• Kickback Risk: A closed rail increases the risk of kickback by impeding the chain’s ability to move freely through the wood. Kickback is a major cause of chainsaw-related injuries. According to the Consumer Product Safety Commission (CPSC), chainsaws cause approximately 30,000 injuries annually in the United States alone, many of which are due to kickback.
• Lubrication Efficiency: A restricted chain path due to closed rails reduces the effectiveness of the bar and chain oil, leading to increased friction and heat.

Correcting a Closed Chainsaw Bar Rail

Essential Tools and Materials

Before attempting to fix a closed bar rail, gather the necessary tools and materials:

• Chainsaw Bar Rail Spreader: This specialized tool is designed to gently pry open the rails without causing further damage. I prefer a spreader with adjustable settings to accommodate different bar sizes.
• Flat File: A high-quality flat file is essential for removing burrs and smoothing any imperfections on the bar rails. I recommend a file with a fine tooth pattern for precision work.
• Mill Bastard File: For more significant rail closure, a mill bastard file can be used to remove larger amounts of material. However, use this file with caution to avoid over-filing.
• Straightedge: A metal straightedge is crucial for checking the alignment of the bar rails after making adjustments. I use a 12-inch straightedge for most chainsaw bars.
• Vise: A sturdy vise is needed to hold the bar securely while working on it. I prefer a vise with soft jaws to prevent scratching the bar.
• Hammer: A small hammer can be used to gently tap the bar spreader into place.
• Lubricating Oil: Apply lubricating oil to the bar rails after making adjustments to reduce friction and prevent rust. I use the same oil I use for the chain and bar.
• Safety Glasses: Always wear safety glasses when working with tools to protect your eyes from flying debris.
• Gloves: Wear gloves to protect your hands from sharp edges and oil.
• Cleaning Supplies: Clean rags or paper towels are needed to wipe away dirt and oil.

Step-by-Step Repair Process

Here’s a detailed, step-by-step guide on how to fix a closed chainsaw bar rail:

1. Preparation:
   • Disconnect the chainsaw from the power source (unplug electric saws or remove the spark plug wire on gas-powered saws).
   • Remove the chain and bar from the chainsaw.
   • Clean the bar thoroughly with a wire brush and degreaser to remove any dirt, sawdust, or oil. This will allow you to better inspect the rails.
2. Assessment:
   • Carefully examine the bar rails for any signs of pinching or inward bending. Use a straightedge to identify areas where the rails are not parallel.
   • Check for any burrs or imperfections on the rails.
3. Initial Correction with Bar Rail Spreader:
   • Place the chainsaw bar in the vise, ensuring it is held securely but not overly tightened.
   • Insert the bar rail spreader into the closed section of the rail.
   • Gently widen the rails using the spreader, working slowly and carefully to avoid over-spreading or damaging the bar. I usually start with small adjustments and gradually increase the spread until the rails are parallel.
   • Use a straightedge to check the alignment of the rails after each adjustment.
4. Filing the Rails:
   • If the rails are uneven or have burrs, use a flat file to smooth them out. Hold the file at a slight angle and move it along the rail in a smooth, even motion.
   • For more significant rail closure, use a mill bastard file to remove larger amounts of material. However, be careful not to over-file, as this can weaken the bar.
   • Periodically check the alignment of the rails with a straightedge and adjust your filing technique as needed.
5. Final Adjustments and Smoothing:
   • After filing, use the flat file to smooth any rough edges or imperfections on the rails.
   • Apply lubricating oil to the bar rails to reduce friction and prevent rust.
6. Reassembly and Testing:
   • Reinstall the chain and bar on the chainsaw.
   • Adjust the chain tension to the proper specification.
   • Start the chainsaw and test its performance. Check for smooth cutting, even chip ejection, and proper chain lubrication.

Case Study: Reviving a Severely Damaged Bar

I once salvaged a chainsaw bar that had suffered significant rail closure due to overheating and improper chain tension. The bar was from a Stihl MS 290, a common model used for firewood cutting. The owner had neglected to maintain proper chain tension and had been running the saw at full throttle for extended periods while cutting large oak logs. As a result, the rails were severely pinched together, making it nearly impossible to install the chain.

Here’s how I approached the repair:

1. Initial Assessment: The bar was heavily discolored from heat and the rails were visibly pinched. I used a straightedge to confirm the extent of the closure, which was approximately 0.040 inches in the worst area.
2. Spreading the Rails: I used a heavy-duty bar rail spreader with adjustable settings. Due to the severity of the closure, I had to apply significant force to widen the rails. I worked slowly and carefully, making small adjustments and checking the alignment with a straightedge after each adjustment.
3. Filing: After spreading the rails, I used a mill bastard file to remove the high spots and smooth out the uneven surfaces. I paid particular attention to the areas where the rails had been pinched together, as these areas were often work-hardened and more difficult to file.
4. Finishing: After filing, I used a flat file to smooth any rough edges and imperfections. I then applied lubricating oil to the rails to reduce friction and prevent rust.
5. Testing: I reinstalled the chain and bar on the chainsaw and tested its performance. The saw now cut smoothly and evenly, and the chain ran freely without binding.

The repair took approximately 2 hours to complete, but it saved the owner the cost of a new bar, which would have been around \$75. This case study demonstrates that even severely damaged chainsaw bars can often be salvaged with the right tools and techniques.

Tool Calibration Standards

Ensuring your tools are calibrated and in good working order is essential for accurate and safe chainsaw bar rail repair. Here are some calibration standards and maintenance tips:

• Bar Rail Spreader: Check the spreader’s jaws for wear or damage. Replace the spreader if the jaws are worn or distorted, as this can lead to inaccurate spreading and potential damage to the bar. I periodically lubricate the moving parts of my spreader with a light machine oil to ensure smooth operation.
• Files: Keep your files clean and sharp. Use a file card to remove any metal shavings or debris that may clog the file’s teeth. Replace your files when they become dull, as dull files can be difficult to use and can produce inaccurate results. I store my files in a dry place to prevent rust.
• Straightedge: Check the straightedge for straightness. Use a known straight surface (such as a granite countertop) to verify the straightness of the straightedge. Replace the straightedge if it is bent or warped.
• Vise: Ensure the vise is securely mounted and that the jaws are in good condition. Replace the vise if the jaws are worn or damaged, as this can lead to slippage and potential injury. I periodically lubricate the vise’s moving parts with a heavy grease to ensure smooth operation.

Preventing Bar Rail Closure

Prevention is always better than cure. Here are some tips for preventing bar rail closure:

• Proper Chain Tension: Maintain proper chain tension at all times. Check the chain tension regularly and adjust it as needed. A properly tensioned chain should be snug against the bar but should still be able to be pulled around the bar by hand.
• Adequate Lubrication: Ensure the bar and chain are adequately lubricated at all times. Check the oil level frequently and refill as needed. Use a high-quality bar and chain oil that is specifically designed for chainsaws. I prefer synthetic oils, as they provide superior lubrication and protection.
• Avoid Overheating: Avoid overheating the bar by cutting in short bursts and allowing the saw to cool down periodically. Don’t force the saw through the wood, and avoid cutting excessively hard or knotty wood.
• Sharp Chain: Keep the chain sharp. A dull chain requires more force to cut, which can put excessive stress on the bar. Sharpen the chain regularly or replace it when it becomes too dull.
• Proper Storage: Store the chainsaw properly when not in use. Store the saw horizontally, with the bar supported to prevent any bending or warping. I also recommend using a bar cover to protect the bar from dust and debris.
• Regular Maintenance: Perform regular maintenance on the chainsaw, including cleaning the bar, checking the sprocket, and lubricating the moving parts. A well-maintained chainsaw will last longer and perform better.
• Avoid Impact: Be careful to avoid hitting rocks, metal objects, or knots in the wood. These impacts can damage the bar and contribute to rail closure.

Data Points and Statistics

• Chain Sharpness and Cutting Efficiency: Studies have shown that a sharp chain can increase cutting efficiency by as much as 30%. This translates to faster cutting, reduced fuel consumption, and less stress on the bar.
• Lubrication and Bar Temperature: Proper lubrication can reduce bar temperature by as much as 50°F. This can significantly reduce the risk of overheating and warping.
• Chain Tension and Bar Wear: Maintaining proper chain tension can reduce bar wear by as much as 25%. This can extend the life of the bar and save you money on replacements.
• Storage and Bar Rust: Storing the chainsaw properly can prevent rust and corrosion, which can weaken the bar and reduce its lifespan. A bar cover can provide additional protection against the elements.

Wood Selection Criteria and Technical Limitations

Understanding Wood Properties

The type of wood you are cutting can significantly impact the performance of your chainsaw and the likelihood of bar rail closure. Different wood species have different densities, hardnesses, and moisture contents, all of which can affect cutting efficiency and bar wear.

• Hardwoods vs. Softwoods: Hardwoods, such as oak, maple, and hickory, are generally denser and harder than softwoods, such as pine, fir, and cedar. Hardwoods require more power to cut and can generate more heat, increasing the risk of bar rail closure. Softwoods are easier to cut but can be more prone to splintering.
• Moisture Content: The moisture content of wood can also affect cutting performance. Green wood (freshly cut wood) has a higher moisture content than seasoned wood (wood that has been dried). Green wood is generally easier to cut but can be heavier and more difficult to split. Seasoned wood is lighter and easier to split but can be more difficult to cut if it is too dry. The ideal moisture content for firewood is typically between 15% and 20%.

Log Dimensions and Cord Volumes

When processing wood for firewood or other purposes, it’s important to understand log dimensions and cord volumes. A cord is a standard unit of measurement for firewood, defined as a stack of wood that is 4 feet high, 4 feet wide, and 8 feet long, or 128 cubic feet. A face cord (also known as a rick or a stove cord) is a stack of wood that is 4 feet high and 8 feet long but is only one log deep. The volume of a face cord depends on the length of the logs.

• Log Diameter: The diameter of the logs you are cutting can affect the amount of stress on the chainsaw bar. Cutting logs with larger diameters requires more power and can generate more heat, increasing the risk of bar rail closure.
• Log Length: The length of the logs you are cutting can affect the stability of the chainsaw. Cutting long logs can be more difficult and dangerous than cutting short logs.
• Industry Standards: The American National Standards Institute (ANSI) has established standards for wood processing and logging safety. These standards cover a wide range of topics, including chainsaw operation, personal protective equipment, and safe work practices.

Technical Requirements for Firewood

Producing high-quality firewood requires adherence to certain technical requirements.

• Moisture Content: As mentioned earlier, the ideal moisture content for firewood is between 15% and 20%. Wood with a higher moisture content will be difficult to burn and will produce excessive smoke. Wood with a lower moisture content will burn too quickly and will not produce as much heat.
• Drying Time: The drying time for firewood depends on the type of wood, the climate, and the storage conditions. In general, hardwoods take longer to dry than softwoods. In a dry climate, firewood may dry in as little as six months. In a humid climate, it may take a year or more.
• Storage Conditions: Firewood should be stored in a dry, well-ventilated area. Stacking the wood off the ground and covering it with a tarp can help to prevent moisture from seeping into the wood.

Data Points and Statistics

• Wood Density and Heat Value: The heat value of wood is directly related to its density. Denser woods, such as oak and maple, have a higher heat value than less dense woods, such as pine and fir. A cord of oak can produce as much as 50% more heat than a cord of pine.
• Moisture Content and Burning Efficiency: Wood with a moisture content above 20% can lose as much as 25% of its heat value due to the energy required to evaporate the water.
• Drying Time and Wood Decay: Wood that is not properly dried can be susceptible to decay. Decay can reduce the heat value of the wood and make it more difficult to burn.

Safety Equipment Requirements

Safety is paramount when operating a chainsaw. Always wear appropriate personal protective equipment (PPE) to minimize the risk of injury.

• Helmet: A hard hat is essential for protecting your head from falling branches and other debris. I prefer a helmet with a face shield and ear protection.
• Eye Protection: Safety glasses or a face shield are necessary to protect your eyes from flying sawdust and debris.
• Ear Protection: Chainsaws are very loud, and prolonged exposure to high noise levels can damage your hearing. Wear earplugs or earmuffs to protect your ears.
• Gloves: Gloves protect your hands from cuts, scrapes, and blisters. I prefer leather gloves with reinforced palms.
• Chainsaw Chaps: Chainsaw chaps are designed to protect your legs from chainsaw cuts. They are made from multiple layers of ballistic nylon that can stop a chainsaw chain in its tracks.
• Steel-Toed Boots: Steel-toed boots protect your feet from falling logs and other hazards.
• First-Aid Kit: Keep a well-stocked first-aid kit on hand in case of injury.

Safety Codes

Adhere to all applicable safety codes and regulations. These codes are designed to protect workers from injury and to ensure safe working conditions.

• OSHA Regulations: The Occupational Safety and Health Administration (OSHA) has established regulations for logging and wood processing. These regulations cover a wide range of topics, including chainsaw operation, personal protective equipment, and safe work practices.
• State and Local Regulations: Many states and local governments have their own safety codes and regulations for logging and wood processing. Be sure to familiarize yourself with the regulations in your area.

Data Points and Statistics

• Injury Reduction with PPE: Studies have shown that wearing appropriate PPE can reduce the risk of chainsaw-related injuries by as much as 50%.
• Hearing Loss and Chainsaw Operation: Prolonged exposure to chainsaw noise can lead to permanent hearing loss. Wearing ear protection can significantly reduce the risk of hearing damage.
• Leg Injuries and Chainsaw Chaps: Chainsaw chaps can prevent or reduce the severity of leg injuries in the event of a chainsaw cut.

Conclusion

Maintaining a chainsaw bar with properly aligned rails is essential for safe, efficient, and accurate wood cutting. By understanding the causes of bar rail closure, identifying the symptoms, and following the steps outlined in this guide, you can correct this problem and prevent it from recurring. Remember to always prioritize safety and to adhere to all applicable safety codes and regulations. By investing in the proper tools and equipment, and by taking the time to maintain your chainsaw properly, you can ensure that it will provide you with years of reliable service.

From my years of experience, I can attest that a little preventative maintenance goes a long way. Taking the time to properly care for your chainsaw bar will not only improve its performance but will also extend its lifespan, saving you money in the long run. And, more importantly, it will help to keep you safe while you are working in the woods.

Learn more