DIY Chains for Firewood Cutting (Riveting Tips & Bulk Buying Hacks)

Why Learn to Rivet Chains? My Journey from Frustration to Freedom

I remember the first time I snapped a chain deep in the woods. I was miles from civilization, daylight was fading, and I was staring at a useless saw. That day, I vowed to learn how to repair my own chains. It wasn’t just about the money, although the cost of constantly replacing chains adds up quickly. It was about self-reliance and the freedom to keep working without being at the mercy of a broken chain or a closed hardware store.

Learning to rivet chains was a game-changer. I could now repair damaged chains on the spot, create custom-length chains for different saws, and, most importantly, buy chain in bulk at a fraction of the cost. It’s like having a superpower when you’re out there in the woods.

Understanding the Costs: Breaking Down the Chain Equation

Before we dive into the riveting process, let’s understand the costs involved in buying and maintaining chainsaw chains. The price of a chain depends on several factors:

• Chain Length: Measured by the number of drive links.
• Chain Pitch: The distance between three rivets divided by two. Common pitches are .325″, 3/8″, and .404″.
• Chain Gauge: The thickness of the drive links. Common gauges are .043″, .050″, .058″, and .063″.
• Chain Type: Full chisel, semi-chisel, low-kickback, etc.
• Brand: Stihl, Oregon, Husqvarna, and aftermarket brands.

Typically, a single 16-inch chain from a reputable brand can cost anywhere from $25 to $40. If you’re cutting a lot of firewood, these costs can quickly become substantial. Buying chain in bulk and making your own chains significantly reduces this expense.

Bulk Buying: Unlocking Massive Savings

The key to saving money on chainsaw chains is buying in bulk. Instead of purchasing individual chains, I buy 100-foot rolls of chain. Here’s why this is a smart move:

• Lower Cost Per Foot: A 100-foot roll of chain can cost anywhere from $200 to $500, depending on the chain type and brand. This translates to a cost per foot of $2 to $5, significantly lower than the $1.50 to $2.50 per drive link you might pay buying individual chains.
• Customization: You can make chains of any length, perfectly suited to your saws and cutting needs.
• Reduced Downtime: You always have a supply of chain on hand, ready to be made into a new chain or used for repairs.

Where to Buy Bulk Chain:

• Online Retailers: Amazon, eBay, and specialty chainsaw parts websites.
• Arborist Supply Stores: These stores often offer competitive pricing on bulk chain.
• Direct from Manufacturers: If you’re a high-volume user, consider buying directly from chain manufacturers like Oregon or Stihl.

Data Point: According to a 2023 survey of firewood cutters, those who buy chain in bulk save an average of 40% compared to those who buy individual chains.

My Experience: I switched to buying bulk chain about five years ago, and I estimate I’ve saved well over $1,000 on chain costs alone. The initial investment in a roll of chain and a riveting tool paid for itself within the first year.

The Tools of the Trade: What You’ll Need to Rivet Chains

To rivet your own chains, you’ll need a few essential tools:

• Chain Breaker/Spinning Tool: This tool is used to separate the chain by pushing out the rivets. A good quality chain breaker is crucial for efficient and clean chain disassembly.
• Chain Rivet Spinner/Rivet Closer: This tool flares the ends of the rivets, securing the chain together. A reliable rivet spinner is essential for creating strong and durable chains.
• Stump Vise (Optional but Recommended): A stump vise holds the chain securely while you’re working on it, making the riveting process much easier and safer.
• Hammer and Punch (Optional): Can be used in conjunction with the chain breaker for stubborn rivets.
• Safety Glasses: Always wear safety glasses when working with metal tools.
• Gloves: Protect your hands from sharp chain cutters and metal shavings.
• Chain Grinder (Optional but Highly Recommended): A chain grinder allows you to sharpen your chains quickly and accurately, extending their lifespan.

Cost Breakdown:

• Chain Breaker/Spinning Tool: $50 – $200 (depending on quality and features)
• Stump Vise: $30 – $80
• Hammer and Punch: $10 – $20
• Safety Glasses: $10 – $20
• Gloves: $10 – $20
• Chain Grinder: $100 – $500 (depending on features and brand)

My Recommendation: Invest in a good quality chain breaker and rivet spinner. These are the workhorses of your chain-making operation, and a cheap tool will only lead to frustration and broken chains. The Oregon 520A chain breaker and the Oregon 550 rivet spinner are excellent choices.

The Riveting Process: A Step-by-Step Guide

Now that you have your tools and chain, let’s get to the riveting process. Here’s a step-by-step guide to making your own chainsaw chains:

1. Determine Chain Length:

• Count the number of drive links on your existing chain. This is the most accurate way to determine the correct length.
• Alternatively, consult your chainsaw’s manual or measure the bar length and pitch to determine the appropriate number of drive links.

2. Cut the Chain to Length:

• Use the chain breaker to separate the chain at the desired length.
• Be precise when cutting the chain. It’s better to err on the side of being slightly too long than too short.

3. Assemble the Chain:

• Connect the two ends of the chain using a connecting link.
• Ensure the drive links are facing in the correct direction. The cutting edges should point towards the direction the chain travels around the bar.

4. Rivet the Connecting Link:

• Place the chain in the stump vise, with the connecting link positioned for riveting.
• Use the rivet spinner to flare the ends of the rivets on the connecting link.
• Apply consistent pressure and rotate the spinner until the rivets are securely flared.
• Inspect the rivets to ensure they are properly flared and the chain is securely connected.

5. Check for Smooth Movement:

• After riveting, check the chain for smooth movement. The connecting link should move freely without binding.
• If the chain is stiff, gently tap the connecting link with a hammer to loosen it up.

6. Sharpen the Chain:

• Sharpen the newly made chain using a chain grinder or a hand file.
• Ensure all the cutters are sharpened to the correct angle and depth.

Tips for Success:

• Practice Makes Perfect: Don’t be discouraged if your first few attempts aren’t perfect. Riveting chains takes practice.
• Use a Stump Vise: A stump vise makes the riveting process much easier and safer.
• Apply Consistent Pressure: When using the rivet spinner, apply consistent pressure to ensure the rivets are properly flared.
• Inspect Your Work: Always inspect your work to ensure the chain is securely connected and moves freely.
• Sharpen Regularly: Keep your chains sharp to improve cutting performance and reduce wear and tear.

My Personal Tip: I like to use a small amount of grease on the rivets before spinning them. This helps to ensure a smooth and consistent flare.

Chain Maintenance: Extending the Life of Your Chains

Proper chain maintenance is essential for extending the life of your chains and maximizing your investment. Here are a few tips:

• Sharpen Regularly: Sharpen your chains every time you refuel your saw. A sharp chain cuts faster, smoother, and with less effort.
• Clean Regularly: Clean your chains after each use to remove sawdust and debris. Use a wire brush and solvent to clean the chain thoroughly.
• Lubricate Regularly: Keep your chains well-lubricated. Use a high-quality bar and chain oil.
• Inspect Regularly: Inspect your chains regularly for damage. Look for cracked cutters, loose rivets, and worn drive links.
• Store Properly: Store your chains in a dry place to prevent rust.

Cost of Chain Maintenance:

• Bar and Chain Oil: $10 – $20 per gallon
• Chain Grinder: $100 – $500 (one-time cost)
• Hand File: $10 – $20
• Wire Brush: $5 – $10
• Solvent: $10 – $20 per gallon

Data Point: A well-maintained chain can last up to three times longer than a poorly maintained chain.

Choosing the Right Chain: Matching the Chain to the Wood

The type of chain you use can significantly impact your cutting performance and the lifespan of your chain. Here’s a brief overview of the different types of chainsaw chains:

• Full Chisel Chains: These chains have square-cornered cutters that are very aggressive and cut quickly. They are best suited for clean wood and experienced users.
• Semi-Chisel Chains: These chains have rounded-cornered cutters that are more durable and less prone to dulling. They are a good choice for dirty wood and less experienced users.
• Low-Kickback Chains: These chains are designed to reduce the risk of kickback. They are a good choice for beginners and those who are concerned about safety.

Matching the Chain to the Wood:

• Softwoods (Pine, Fir, Spruce): Full chisel chains are a good choice for softwoods. They cut quickly and efficiently.
• Hardwoods (Oak, Maple, Ash): Semi-chisel chains are a better choice for hardwoods. They are more durable and less prone to dulling.
• Dirty Wood (Wood with Dirt, Bark, or Debris): Semi-chisel chains are the best choice for dirty wood. They are more resistant to abrasion and dulling.

My Recommendation: I use full chisel chains for most of my firewood cutting, as I primarily cut clean hardwoods. However, I switch to semi-chisel chains when I’m cutting dirty wood or working in areas with a lot of debris.

Safety First: Protecting Yourself While Cutting Firewood

Cutting firewood can be a dangerous activity. It’s essential to take precautions to protect yourself from injury. Here are a few safety tips:

• Wear Appropriate Safety Gear: Always wear a helmet, safety glasses, hearing protection, gloves, and chainsaw chaps.
• Use a Chainsaw with Safety Features: Use a chainsaw with a chain brake, anti-vibration system, and a throttle lock.
• Be Aware of Your Surroundings: Be aware of your surroundings and watch out for hazards such as falling trees, branches, and uneven ground.
• Use Proper Cutting Techniques: Use proper cutting techniques to avoid kickback and other hazards.
• Never Cut Above Your Head: Never cut above your head. This is a very dangerous practice.
• Take Breaks: Take breaks to avoid fatigue. Fatigue can lead to accidents.
• Never Cut Alone: Never cut firewood alone. Always have someone with you in case of an emergency.

Cost of Safety Gear:

• Helmet: $50 – $100
• Safety Glasses: $10 – $20
• Hearing Protection: $20 – $50
• Gloves: $10 – $20
• Chainsaw Chaps: $100 – $200

Data Point: According to the U.S. Consumer Product Safety Commission, there are approximately 30,000 chainsaw-related injuries each year.

My Personal Experience: I’ve had a few close calls while cutting firewood. I once had a tree fall in the wrong direction and nearly crush me. Another time, I experienced kickback and nearly lost control of the saw. These experiences have taught me the importance of safety and the need to always be vigilant.

• Timber Purchase or Harvesting Costs: If you’re buying timber, the cost will depend on the species, quality, and volume of wood. If you’re harvesting your own timber, you’ll need to factor in the cost of permits, if applicable.
• Tool Costs: Chainsaw, splitter, wedges, axes, etc.
• Tool Maintenance: Chain sharpening, oil, fuel, repairs.
• Labor Wages: If you’re hiring a logging crew or firewood handlers, you’ll need to pay them wages.
• Transportation Costs: The cost of transporting the firewood from the cutting site to your home.
• Storage Costs: The cost of storing the firewood until it’s ready to be burned.

Cost Breakdown Example (Per Cord of Firewood):

• Timber Purchase (Standing Dead Oak): $50 – $100
• Chainsaw Fuel & Oil: $10 – $20
• Chain Maintenance: $5 – $10
• Splitter Rental (4 Hours): $50 – $100
• Labor (Your Own Time – Estimated): $50 – $100
• Transportation (Truck & Trailer): $20 – $40
• Total Cost Per Cord: $185 – $370

Data Point: The average price per cord of seasoned firewood in the United States ranges from $200 to $400, depending on the region and wood species.

Tips for Cost Optimization:

• Harvest Your Own Timber: If you have access to land, harvesting your own timber can save you a significant amount of money.
• Buy Timber in Bulk: If you’re buying timber, buy it in bulk to get a lower price per cord.
• Rent or Borrow Tools: If you don’t use your tools frequently, consider renting or borrowing them instead of buying them.
• Maintain Your Tools: Properly maintain your tools to extend their lifespan and reduce repair costs.
• Cut and Split Your Own Firewood: Cutting and splitting your own firewood can save you a significant amount of money on labor costs.
• Season Your Firewood Properly: Properly seasoning your firewood will improve its burning efficiency and reduce the amount of wood you need to burn.
• Buy Chains in Bulk and Rivet Your Own: As we’ve discussed, this can save you a significant amount of money on chain costs.

Drying Time: The Hidden Cost of Unseasoned Firewood

One of the most overlooked costs in firewood preparation is the cost of unseasoned wood. Burning unseasoned wood is inefficient and can damage your stove or fireplace. Seasoning firewood takes time and space, but it’s essential for getting the most out of your firewood.

Factors Affecting Drying Time:

• Wood Species: Hardwoods take longer to dry than softwoods.
• Climate: Warmer, drier climates are ideal for seasoning firewood.
• Stacking Method: Proper stacking is essential for air circulation and efficient drying.
• Wood Size: Smaller pieces of wood dry faster than larger pieces.

Estimating Drying Time:

• Hardwoods: Typically take 6-12 months to season properly.
• Softwoods: Typically take 3-6 months to season properly.

Formula for Estimating Drying Time:

• Drying Time (Months) = (Initial Moisture Content – Desired Moisture Content) / Drying Rate

  • Initial Moisture Content: The moisture content of the wood when it’s freshly cut.
  • Desired Moisture Content: The moisture content of the wood when it’s ready to burn (typically 20% or less).
  • Drying Rate: The rate at which the wood loses moisture (varies depending on climate and stacking method).

Cost of Unseasoned Firewood:

• Reduced Burning Efficiency: Unseasoned firewood burns less efficiently, meaning you need to burn more wood to get the same amount of heat.
• Increased Creosote Buildup: Unseasoned firewood produces more creosote, which can build up in your chimney and increase the risk of a chimney fire.
• Damage to Stove or Fireplace: Burning unseasoned firewood can damage your stove or fireplace.

My Recommendation: Always season your firewood properly before burning it. This will save you money in the long run and improve the safety of your home.

Case Study: From Tree to Hearth – A Cost-Effective Firewood Project

Let’s look at a real-world example of a cost-effective firewood project. I recently helped a friend cut and split firewood for his wood stove. Here’s a breakdown of the project:

• Timber Source: Standing dead oak trees on his property.
• Tools: Chainsaw, splitter, wedges, axes.
• Labor: My friend and I worked together.
• Time: We spent two weekends cutting and splitting the wood.
• Yield: We produced approximately 4 cords of firewood.

Cost Breakdown:

• Chainsaw Fuel & Oil: $40
• Chain Maintenance: $20
• Splitter Rental (2 Days): $200
• Labor (Estimated Value of Our Time): $400 (2 people x 2 days x $100/day)
• Transportation: $0 (Wood was processed on-site)
• Total Cost: $660

Cost Per Cord: $165

Savings: The average price per cord of seasoned firewood in our area is $300. By cutting and splitting his own firewood, my friend saved approximately $135 per cord, or $540 total.

Lessons Learned:

• Working Together Saves Time and Money: Working with a friend made the project more efficient and enjoyable.
• Using On-Site Resources Reduces Costs: Using timber from his own property eliminated the cost of purchasing wood.
• Proper Planning is Essential: Planning the project in advance helped us to avoid delays and unexpected expenses.

Actionable Takeaways and Next Steps

Mastering the art of DIY chainsaw chains and bulk buying is a powerful way to reduce your firewood cutting costs. Here’s a summary of the key takeaways and next steps:

1. Research Chain Breakers and Rivet Spinners: Read reviews and compare prices to find the best tools for your needs.
2. Find a Supplier of Bulk Chain: Contact arborist supply stores or online retailers to get quotes on 100-foot rolls of chain.
3. Practice Riveting Chains: Start with a few practice chains to get comfortable with the riveting process.
4. Plan Your Next Firewood Cutting Project: Create a budget and timeline for your next firewood cutting project.

By following these tips and taking the necessary precautions, you can save money, improve your cutting performance, and enjoy the satisfaction of providing your own heat source. And remember, the journey from a pile of logs to a warm fire is a rewarding one, filled with hard work, valuable skills, and the satisfaction of self-reliance. Happy cutting!

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