Husqvarna 592 XP 36 Inch Bar Tips (5 Pro Milling Hacks)

I’ve always been fascinated by the transformation of raw timber into something useful, whether it’s sturdy lumber for building, cozy firewood for a winter’s night, or exquisite milled pieces for woodworking. It’s a process that combines skill, knowledge, and the right tools. Today, I want to share some pro milling hacks using the Husqvarna 592 XP with a 36-inch bar, a powerhouse chainsaw that I’ve come to rely on for serious milling projects. I will cover essential tips and techniques that will help you get the most out of this saw and achieve professional-quality results.

Husqvarna 592 XP: Unleashing Milling Potential

The Husqvarna 592 XP is a beast of a chainsaw, renowned for its power, durability, and efficient design. With a 92cc engine, it delivers the torque needed to handle large-diameter logs, making it an excellent choice for milling. When paired with a 36-inch bar, it offers a substantial cutting capacity, allowing you to tackle a wide range of milling projects.

Why the 592 XP?

Power-to-Weight Ratio: The 592 XP strikes an excellent balance between power and weight, making it manageable for extended milling sessions.
Durability: Husqvarna is known for its robust construction, ensuring the saw can withstand the rigors of milling.
Air Injection: This feature pre-cleans the intake air, reducing wear and tear on the engine and extending its lifespan – a critical factor when dealing with the fine dust produced during milling.
Adjustable Oil Pump: The ability to adjust the oil flow is essential for milling, ensuring the bar and chain are adequately lubricated to prevent overheating and premature wear.

Pro Milling Hack #1: Chain Selection and Preparation

The chain is the heart of any milling operation. Using the right chain and preparing it correctly can significantly impact your cutting speed, accuracy, and the lifespan of your equipment.

Choosing the Right Chain

For milling, I recommend using a ripping chain. Unlike standard crosscut chains designed for felling and bucking, ripping chains are specifically engineered for cutting along the grain of the wood.

Ripping Chain Characteristics: Ripping chains have a unique cutter geometry with a shallower cutting angle (typically 5-10 degrees) compared to crosscut chains (25-35 degrees). This shallower angle allows the chain to slice through the wood fibers more efficiently, resulting in smoother cuts and faster milling speeds.
Chain Pitch and Gauge: Ensure the chain pitch and gauge match your chainsaw and bar specifications. The 592 XP typically uses a .404″ pitch chain with a .063″ gauge, but always double-check your equipment’s manual.

Sharpening for Milling

Proper sharpening is crucial for maximizing the performance of your ripping chain. I’ve found that a consistent and precise sharpening technique can make a world of difference in cutting speed and finish quality.

Maintaining the Correct Angle: Use a chainsaw file guide to maintain the correct cutting angle. For ripping chains, aim for a 5-10 degree angle. Consistency is key – ensure each cutter is sharpened to the same angle and length.
Depth Gauge Adjustment: The depth gauges (or rakers) control the amount of wood each cutter takes per pass. For milling, I recommend setting the depth gauges slightly lower than the manufacturer’s specification. This allows the chain to take a more aggressive bite, increasing cutting speed. However, be cautious not to lower them too much, as this can cause excessive vibration and a rough cut. I typically aim for a depth gauge setting of .025″ – .030″ for milling softwood and .020″ – .025″ for hardwood.
Consistent Filing: Use a consistent filing technique for each cutter. I prefer using a round file with a file guide, making sure to maintain the correct angle and depth. After filing, use a flat file to remove any burrs from the cutters.

Chain Break-In

Breaking in a new chain is essential for extending its lifespan and ensuring optimal performance.

Initial Run: After installing a new chain, run the chainsaw at low speed for a few minutes to allow the chain to stretch and the oil to penetrate the links.
Tension Adjustment: Check the chain tension frequently during the initial run and adjust as needed. A new chain will typically stretch more than a used chain.
Sharpening After Break-In: After the initial run, sharpen the chain to remove any imperfections and ensure all cutters are uniform.

Takeaway: Selecting the right ripping chain, sharpening it precisely, and breaking it in properly are fundamental steps for successful milling with the Husqvarna 592 XP. A well-prepared chain will cut faster, produce smoother results, and last longer.

Pro Milling Hack #2: Mastering Milling Frame Set-Up

A well-configured milling frame is essential for achieving accurate and consistent cuts. Whether you’re using an Alaskan mill or a homemade setup, proper alignment and stability are critical.

Understanding Milling Frames

Milling frames, also known as chainsaw mills, guide the chainsaw along a straight path, allowing you to cut lumber with consistent thickness. There are two primary types of milling frames:

Alaskan Mill: These are commercially available frames that clamp directly onto the chainsaw bar. They are typically adjustable for different board thicknesses and are relatively easy to set up.
Homemade Mill: These are custom-built frames often constructed from wood or metal. They can be tailored to specific log sizes and milling requirements, but require more fabrication skills.

Setting Up the Milling Frame

Regardless of the type of frame you use, the setup process is similar:

Attaching the Frame: Securely attach the milling frame to the chainsaw bar according to the manufacturer’s instructions. Ensure all bolts and clamps are tightened properly to prevent slippage during operation.
Leveling the Log: Before making the first cut, ensure the log is level and stable. Use wedges or shims to support the log and prevent it from rolling. This is crucial for achieving consistent board thickness.
Setting the Cutting Depth: Adjust the milling frame to the desired board thickness. Use a measuring tape or ruler to ensure accurate settings.
Guide Rails: The first cut (the “reference cut”) is the most critical, as it establishes the flat surface that subsequent cuts will follow. For the reference cut, you’ll need to use guide rails. These can be made from straight lumber (2x4s or 2x6s work well) or metal tracks.
- Attaching Guide Rails: Securely attach the guide rails to the top of the log using screws or clamps. Ensure the rails are perfectly parallel and level. Use a level and measuring tape to verify alignment.
- Alternative Method: I have found that using two ladders placed parallel to each other and bridging them with straight 2x4s works exceptionally well for setting up the guide rails, especially for longer logs. This provides a stable and adjustable platform for the milling frame to glide along.
Cutting the Reference Cut: With the milling frame resting on the guide rails, make the first cut. Maintain a slow and steady pace, allowing the chainsaw to do the work. Avoid forcing the saw, as this can lead to uneven cuts and increased wear on the chain.

Optimizing Frame Stability

Support the Log: Use additional supports, such as sawhorses or log bunks, to prevent the log from sagging or moving during milling.
Secure the Frame: Periodically check the milling frame for any signs of looseness or misalignment. Tighten bolts and clamps as needed.
Vibration Dampening: Consider using vibration-dampening materials, such as rubber pads, between the milling frame and the chainsaw to reduce vibration and improve operator comfort.

Takeaway: A properly set up and stable milling frame is essential for achieving accurate and consistent cuts. Take the time to level the log, align the guide rails, and secure the frame before each milling session.

Pro Milling Hack #3: Fine-Tuning the Oiling System

Adequate lubrication is crucial for preventing overheating and premature wear on the bar and chain during milling. The Husqvarna 592 XP features an adjustable oil pump, allowing you to fine-tune the oil flow to match the demands of your milling operation.

Understanding Oiling System Requirements

Milling places significantly higher demands on the chainsaw’s oiling system compared to typical felling or bucking. The continuous cutting action and the fine sawdust produced during milling can quickly deplete the oil supply, leading to increased friction and heat.

Increased Oil Consumption: Milling typically consumes more oil than other chainsaw operations. Be prepared to refill the oil tank more frequently.
Oil Type: Use a high-quality bar and chain oil specifically designed for chainsaws. Avoid using motor oil or other substitutes, as they may not provide adequate lubrication and can damage the oil pump. I prefer using a synthetic bar and chain oil, especially in cold weather, as it flows more easily and provides better protection.

Adjusting the Oil Pump

The Husqvarna 592 XP has an adjustable oil pump that allows you to increase or decrease the oil flow to the bar and chain.

Locating the Adjustment Screw: The oil pump adjustment screw is typically located on the bottom of the chainsaw, near the bar mount. Refer to your owner’s manual for the exact location.
Adjusting the Oil Flow: Use a screwdriver to turn the adjustment screw. Turning the screw clockwise typically decreases the oil flow, while turning it counterclockwise increases the flow.
Testing the Oil Flow: After making an adjustment, run the chainsaw at full throttle and observe the oil flow. You should see a steady stream of oil being ejected from the bar. If the oil flow is insufficient, increase the flow by turning the adjustment screw counterclockwise. If the oil flow is excessive, decrease the flow by turning the screw clockwise.
Optimal Oil Flow: The optimal oil flow will vary depending on the wood species, bar length, and cutting conditions. As a general guideline, you should see a light sheen of oil on the bar and chain after each cut. If the bar is smoking or the chain is turning blue, the oil flow is insufficient.

Maintaining the Oiling System

Clean the Oil Pump: Periodically clean the oil pump and oil filter to remove any debris that may be clogging the system.
Check the Oil Line: Inspect the oil line for any cracks or leaks. Replace the oil line if necessary.
Bar Maintenance: Regularly clean the bar groove and oil holes to ensure proper oil distribution. Use a bar groove cleaner or a small screwdriver to remove any sawdust or debris.

My Personal Experience

I once encountered a severe issue while milling a large oak log. Despite having what I thought was sufficient oil flow, the bar started smoking and the chain began to discolor. I quickly realized the oil pump was partially clogged with fine sawdust. After disassembling and thoroughly cleaning the oil pump, the problem was resolved. This experience taught me the importance of regular oiling system maintenance, especially when milling dense hardwoods.

Takeaway: Fine-tuning the oiling system on your Husqvarna 592 XP is essential for preventing overheating and premature wear during milling. Adjust the oil flow to match the demands of your operation and maintain the oiling system regularly.

Pro Milling Hack #4: Optimizing Cutting Techniques

Efficient cutting techniques can significantly improve your milling speed, accuracy, and overall productivity. Here are some tips and tricks I’ve learned over the years.

Planning Your Cuts

Before you start milling, take the time to plan your cuts. This will help you minimize waste, maximize yield, and avoid potential problems.

Log Assessment: Examine the log carefully to identify any defects, such as knots, cracks, or rot. Plan your cuts to avoid these areas whenever possible.
Grain Orientation: Consider the grain orientation of the wood. For certain applications, such as furniture making, you may want to orient the grain in a specific direction.
Cut List: Create a cut list that specifies the dimensions of the boards you want to produce. This will help you stay organized and avoid making unnecessary cuts.

Maintaining a Steady Pace

Consistency is key when milling. Maintain a slow and steady pace, allowing the chainsaw to do the work. Avoid forcing the saw, as this can lead to uneven cuts and increased wear on the chain.

Listen to the Saw: Pay attention to the sound of the chainsaw. If the saw is bogging down or struggling to cut, reduce the feed rate.
Avoid Pinching: Pinching occurs when the kerf (the width of the cut) closes in on the bar, causing it to bind. To avoid pinching, use wedges to keep the kerf open.
Cutting Direction: When possible, cut with the grain of the wood. This will result in smoother cuts and less strain on the chainsaw.

Dealing with Hardwoods

Milling hardwoods, such as oak or maple, can be more challenging than milling softwoods. Hardwoods are denser and more abrasive, which can cause increased wear on the chain and bar.

Sharper Chain: Ensure your chain is razor-sharp when milling hardwoods. A dull chain will struggle to cut through the dense wood fibers, leading to increased friction and heat.
Slower Feed Rate: Reduce the feed rate when milling hardwoods. This will allow the chain to cut more efficiently and reduce the risk of overheating.
Increased Lubrication: Increase the oil flow to the bar and chain when milling hardwoods. This will help to keep the bar and chain cool and prevent premature wear.

Using Wedges Effectively

Wedges are an essential tool for milling. They help to keep the kerf open, prevent pinching, and support the log during cutting.

Placement: Place wedges strategically along the kerf to prevent it from closing. Start with one wedge near the beginning of the cut and add additional wedges as needed.
Material: Use plastic or wooden wedges. Avoid using metal wedges, as they can damage the chain if they come into contact with it.
Tapping: Use a hammer or mallet to gently tap the wedges into place. Avoid driving them in too forcefully, as this can cause the log to split.

My Biggest Mistake

Early in my milling endeavors, I was impatient and tried to force the chainsaw through a large oak log. The result was a severely pinched bar, a broken chain, and a bruised ego. I learned the hard way that patience and proper technique are essential for successful milling.

Takeaway: Optimizing your cutting techniques can significantly improve your milling speed, accuracy, and overall productivity. Plan your cuts, maintain a steady pace, and use wedges effectively to prevent pinching.

Pro Milling Hack #5: Mastering Post-Milling Wood Management

Milling is only the first step in the process of transforming logs into usable lumber. Proper post-milling wood management is crucial for preventing warping, cracking, and other defects.

Stacking and Sticking Lumber

After milling, the lumber needs to be properly stacked and stickered to allow for air circulation and even drying.

Location: Choose a well-ventilated location for stacking the lumber. Avoid stacking lumber in direct sunlight or in areas with high humidity.
Foundation: Create a solid foundation for the lumber stack using concrete blocks or treated lumber. Ensure the foundation is level to prevent the lumber from warping.
Stickers: Stickers are thin strips of wood (typically 1″ x 1″) that are placed between the layers of lumber to create air gaps. Use dry stickers to prevent the lumber from absorbing moisture.
Stacking Pattern: Stack the lumber in a consistent pattern, ensuring that the stickers are aligned vertically. This will help to distribute the weight evenly and prevent warping.
Spacing: Space the stickers 12-18 inches apart for softwoods and 8-12 inches apart for hardwoods.
Weighting: Place weights on top of the lumber stack to help prevent warping. Concrete blocks, sandbags, or even large rocks can be used for this purpose.

Monitoring Moisture Content

The moisture content of the lumber is a critical factor in its stability and usability. Use a moisture meter to monitor the moisture content of the lumber during the drying process.

Target Moisture Content: The target moisture content for lumber will vary depending on its intended use. For interior applications, aim for a moisture content of 6-8%. For exterior applications, a moisture content of 12-15% may be acceptable.
Drying Time: The drying time for lumber will vary depending on the wood species, thickness, and environmental conditions. As a general guideline, air-drying lumber takes approximately one year per inch of thickness.

Preventing Wood Decay

Wood decay is a common problem that can occur during the drying process. To prevent wood decay, take the following precautions:

Proper Ventilation: Ensure the lumber stack is well-ventilated to promote air circulation and prevent moisture buildup.
Fungicides: Consider treating the lumber with a fungicide to prevent fungal growth.
Insect Control: Protect the lumber from insects, such as termites and beetles, by treating it with an insecticide or by storing it in a pest-free environment.

My Biggest Blunder

I once stacked a large quantity of freshly milled pine lumber in a damp, poorly ventilated location. Within a few weeks, the lumber was covered in mold and mildew, and much of it was unusable. This experience taught me the importance of proper stacking and stickering techniques.

Takeaway: Proper post-milling wood management is crucial for preventing warping, cracking, and other defects. Stack and sticker the lumber correctly, monitor the moisture content, and take precautions to prevent wood decay.

Bonus Tip: Safety First

Milling can be a dangerous activity if proper safety precautions are not followed. Always wear appropriate personal protective equipment (PPE), including:

Safety Glasses: Protect your eyes from flying debris.
Hearing Protection: Chainsaws are loud. Protect your hearing with earplugs or earmuffs.
Gloves: Protect your hands from cuts and abrasions.
Steel-Toed Boots: Protect your feet from falling logs and sharp objects.
Chainsaw Chaps: Protect your legs from chainsaw cuts.

Safe Operating Practices

Read the Manual: Familiarize yourself with the operating manual for your chainsaw and milling frame.
Inspect Equipment: Before each milling session, inspect your chainsaw and milling frame for any signs of damage or wear.
Clear the Area: Clear the milling area of any obstacles or hazards.
Work with a Partner: Whenever possible, work with a partner. This will provide an extra set of eyes and hands in case of an emergency.
Stay Alert: Pay attention to your surroundings and avoid distractions.
Take Breaks: Milling can be physically demanding. Take frequent breaks to avoid fatigue.

Emergency Preparedness

First Aid Kit: Keep a well-stocked first aid kit on hand.
Communication: Have a reliable means of communication, such as a cell phone or two-way radio.
Emergency Plan: Develop an emergency plan in case of an accident.

Conclusion

Milling with the Husqvarna 592 XP and a 36-inch bar can be a rewarding experience, allowing you to transform raw logs into beautiful and useful lumber. By following these pro milling hacks, you can improve your efficiency, accuracy, and safety. Remember to always prioritize safety and take the time to learn the proper techniques. With practice and patience, you’ll be milling like a pro in no time!