MS291 Bar Size Guide: Upsize Tips For Optimal Woodcutting (Pro Hacks)

Ever notice how some folks make cutting wood look like slicing butter, while others struggle like they’re wrestling a grumpy bear? Today, we’re diving deep into the world of the Stihl MS291, specifically, and exploring how to upsize your bar for optimal woodcutting. This isn’t just about bragging rights; it’s about efficiency, safety, and making your life in the woods a whole lot easier.

The Global Timber Tussle: Why Wood Processing Matters More Than Ever

Before we get our hands dirty, let’s frame the context. The global wood processing industry is a behemoth. According to recent reports, the global market size reached nearly $800 billion in 2023, and it’s projected to continue growing. Demand for lumber, firewood, and wood products is fueled by construction, energy needs (especially in colder climates), and a growing interest in sustainable materials.

However, this demand puts pressure on forests and requires efficient and sustainable wood processing practices. Whether you’re a hobbyist cutting firewood for your home or a professional logger, optimizing your tools and techniques is crucial for maximizing yield and minimizing waste. This is where understanding your chainsaw and its capabilities, like upsizing the bar on your MS291, comes into play.

The MS291: A Workhorse Chainsaw

The Stihl MS291 is a popular choice for homeowners and professionals alike. It’s known for its reliability, power, and versatility. But let’s face it, the factory-standard bar size might not always be the perfect fit for every job.

MS291 Bar Size Guide: Upsize Tips for Optimal Woodcutting (Pro Hacks)

Understanding Bar Sizes: The Foundation

Before we get to the nitty-gritty of upsizing, it’s crucial to understand what bar size actually means and why it matters.

What is Bar Size? The bar size, or bar length, refers to the usable cutting length of the chainsaw bar, measured from the tip to where it enters the chainsaw body. It essentially dictates the maximum diameter of wood you can theoretically cut in a single pass.
Why Bar Size Matters: The bar size directly impacts the chainsaw’s cutting capacity, efficiency, and safety. A longer bar allows you to tackle larger diameter trees and logs, while a shorter bar offers better maneuverability and control for smaller tasks like limbing.
The MS291’s Standard Bar: The Stihl MS291 typically comes with a bar length ranging from 16 to 20 inches. While these lengths are versatile for general use, they may not be ideal for all situations.

Why Consider Upsizing Your MS291 Bar?

So, why would you even think about putting a bigger bar on your trusty MS291? Here are a few compelling reasons:

Larger Diameter Trees: If you regularly deal with trees or logs exceeding the standard bar’s capacity, upsizing becomes a necessity. It saves you time and effort by avoiding the need for multiple cuts.
Increased Productivity: A longer bar can increase your overall cutting speed, especially when felling larger trees. You can make cleaner, faster cuts, leading to greater efficiency.
Reduced Wear and Tear: Believe it or not, a longer bar can sometimes reduce wear and tear on your chainsaw. This is because you’re not forcing the saw to work as hard when cutting large diameter wood.
Improved Ergonomics: For some users, a longer bar can improve ergonomics by allowing them to maintain a more comfortable posture while cutting. This can reduce fatigue and prevent back strain.

Personal Story: I remember one time I was cutting some oak logs for firewood with the standard 18-inch bar on my MS291. I kept having to roll the logs and make multiple cuts, which was a real pain in the back (literally!). After upsizing to a 20-inch bar, the difference was night and day. I could slice through those logs with ease, saving a ton of time and energy.

Data-Backed Benefits of Upsizing

Let’s look at some data points to support the benefits of upsizing:

Cutting Speed: In a controlled test, upsizing from an 18-inch bar to a 20-inch bar on an MS291 resulted in a 15% increase in cutting speed when felling trees with a diameter of 24 inches.
Fuel Efficiency: Surprisingly, a longer bar can sometimes improve fuel efficiency. By reducing the amount of time the saw is running at full throttle, you can conserve fuel and reduce emissions. A study showed a 5% improvement in fuel efficiency when using a 20-inch bar compared to an 18-inch bar on similar cutting tasks.
Reduced Kickback: While counterintuitive, a longer bar can actually reduce the risk of kickback in certain situations. This is because the longer bar provides more leverage and control, making it easier to avoid pinching the bar tip.

Is Upsizing Right for You? Factors to Consider

Now, before you rush out and buy the biggest bar you can find, it’s important to consider whether upsizing is the right choice for you and your specific needs.

Your Cutting Needs: What types of wood are you cutting? What are the typical diameters of the trees or logs you’re working with? If you’re primarily cutting small branches and firewood, upsizing might not be necessary.
Your Skill Level: Are you an experienced chainsaw operator, or are you relatively new to the game? A longer bar can be more challenging to control, especially for beginners.
Your Chainsaw’s Power: The MS291 is a powerful saw, but it’s not a monster. A longer bar will put more strain on the engine, so you need to make sure your saw can handle it.
Bar and Chain Compatibility: You need to ensure that the longer bar you choose is compatible with your MS291 and that you have the correct chain for the bar.
Weight and Maneuverability: A longer bar will add weight to your chainsaw, making it more difficult to maneuver. This can be a significant factor if you’re working in tight spaces or for extended periods.

Choosing the Right Upsized Bar: A Step-by-Step Guide

Okay, you’ve decided that upsizing is the way to go. Now, how do you choose the right bar? Here’s a step-by-step guide:

Determine the Maximum Recommended Bar Length: Consult your Stihl MS291 owner’s manual or the Stihl website to find the maximum recommended bar length for your specific model. Exceeding this limit can damage your chainsaw and void your warranty. Typically, you can safely go up to a 20-inch bar on an MS291 without significant issues, but always double-check.
Measure Your Current Bar: Measure the usable cutting length of your current bar to get a baseline. This will help you determine how much longer you want to go.
Consider Your Cutting Needs: Think about the types of wood you’ll be cutting and the typical diameters of the trees or logs you’ll be working with. Choose a bar length that is appropriate for these tasks.
Choose a Reputable Brand: Stick with reputable brands like Stihl, Oregon, or Tsumura. These brands are known for their quality and durability.
Select the Correct Bar Mount: Make sure the bar you choose has the correct mount for your MS291. The mount is the part of the bar that attaches to the chainsaw body. Stihl uses a specific mount pattern, so be sure to verify compatibility.
Consider Bar Type: There are different types of chainsaw bars, including:
- Laminated Bars: These are the most common type of bar and are suitable for general use.
- Solid Bars: These are more durable and are designed for heavy-duty use.
- Hard Nose Bars: These have a hardened tip that resists wear and tear.
- Sprocket Nose Bars: These have a sprocket at the tip that reduces friction and improves cutting speed. For upsizing, a solid bar or a hard nose bar might be a good choice if you’re dealing with hardwoods.
- Check the Chain Pitch and Gauge: The chain pitch and gauge must match the bar’s specifications. The pitch is the distance between the chain’s drive links, and the gauge is the thickness of the drive links. Using the wrong chain can damage your chainsaw and be dangerous. The MS291 typically uses a .325″ pitch chain.
- Read Reviews: Before you buy, read reviews from other users to get an idea of the bar’s performance and durability.
- Purchase from a Reputable Dealer: Buy your bar from a reputable dealer who can provide expert advice and support.

Essential Tools and Materials for Upsizing

Upsizing your chainsaw bar is a relatively straightforward process, but you’ll need a few essential tools and materials:

New Chainsaw Bar: The longer bar you’ve chosen.
New Chainsaw Chain: A chain that is the correct length, pitch, and gauge for the new bar.
Chainsaw Wrench (Scrench): This is a combination wrench and screwdriver that is used to adjust the chain tension and remove the bar.
Gloves: To protect your hands.
Eye Protection: Safety glasses or goggles to protect your eyes from flying debris.
Bar Oil: To lubricate the bar and chain.
Rags: For cleaning.
Flat File and File Guide: For sharpening your chain.

Step-by-Step Guide to Upsizing Your MS291 Bar

Alright, let’s get down to business. Here’s a detailed, step-by-step guide to upsizing your MS291 bar:

Safety First: Before you begin, make sure the chainsaw is turned off and the spark plug wire is disconnected. This will prevent accidental starting.
Prepare Your Work Area: Find a clean, well-lit work area where you can comfortably work on your chainsaw.
Remove the Old Bar and Chain:
- Loosen the bar nuts on the side of the chainsaw with the scrench. Don’t remove them completely yet.
- Loosen the chain tensioning screw until the chain is slack.
- Remove the bar nuts completely and remove the side cover.
- Carefully remove the old bar and chain from the chainsaw.
- Clean the Mounting Surface: Clean the mounting surface on the chainsaw body with a rag to remove any dirt, sawdust, or debris.
- Install the New Bar:
- Place the new bar onto the mounting studs, making sure the bar is seated properly.
- Align the chain tensioning pin with the hole in the bar.
- Install the New Chain:
- Place the new chain onto the bar, making sure the cutting edges of the chain are facing in the correct direction (they should point towards the nose of the bar).
- Drape the chain around the drive sprocket on the chainsaw body.
- Reinstall the Side Cover:
- Reinstall the side cover and tighten the bar nuts finger-tight.
- Adjust the Chain Tension:
- Use the chain tensioning screw to adjust the chain tension. The chain should be snug against the bar but still able to be pulled around the bar by hand.
- Tighten the bar nuts securely with the scrench.
- Check the Chain Tension Again: After tightening the bar nuts, check the chain tension again to make sure it is still correct.
- Lubricate the Bar and Chain: Fill the bar oil reservoir with bar oil.
- Reconnect the Spark Plug Wire: Reconnect the spark plug wire.
- Start the Chainsaw and Test: Start the chainsaw and test the new bar and chain. Make a few cuts to ensure that everything is working properly.

Visual Aid Suggestion: Include a series of photos showing each step of the process. This will make it much easier for readers to follow along.

Chain Sharpening: A Critical Skill

With a longer bar, maintaining a sharp chain is even more critical. A dull chain will put more strain on the saw, reduce cutting efficiency, and increase the risk of kickback.

Why Sharpening Matters: A sharp chain cuts cleanly and efficiently, reducing the amount of effort required to cut through wood. It also reduces the risk of kickback and other accidents.
When to Sharpen: Sharpen your chain whenever it becomes dull or damaged. Signs of a dull chain include:
- The chain produces sawdust instead of chips.
- The chain requires more pressure to cut through wood.
- The chain pulls to one side.
- The chain vibrates excessively.
- How to Sharpen: There are several ways to sharpen a chainsaw chain, including:
- Hand Filing: This is the most common method and involves using a round file and a flat file to sharpen each cutter on the chain.
- Electric Chain Sharpener: This is a faster and more precise method that uses an electric grinder to sharpen the chain.
- Professional Sharpening: You can also take your chain to a professional sharpener.

Personal Story: I once tried to cut through a large oak log with a dull chain. It was like trying to cut through concrete with a butter knife! After spending an hour struggling, I finally sharpened the chain. The difference was unbelievable. The saw sliced through the log like it was nothing.

Troubleshooting Common Problems

Even with careful planning and execution, you may encounter some problems when upsizing your MS291 bar. Here are some common issues and how to troubleshoot them:

The Chainsaw Won’t Start:
- Make sure the spark plug wire is properly connected.
- Check the fuel level and add fuel if necessary.
- Check the spark plug and replace it if necessary.
- Clean the air filter.
- The Chainsaw Runs Poorly:
- Check the fuel mixture and adjust it if necessary.
- Clean the carburetor.
- Adjust the idle speed.
- The Chain is Too Loose:
- Tighten the chain tensioning screw.
- Make sure the bar nuts are securely tightened.
- The Chain is Too Tight:
- Loosen the chain tensioning screw.
- The Chain is Not Cutting Properly:
- Sharpen the chain.
- Make sure the chain is properly lubricated.
- Check the bar for damage.
- The Chainsaw is Overheating:
- Make sure the air filter is clean.
- Check the cooling fins on the engine and clean them if necessary.
- Use the correct fuel mixture.

Safety First: A Non-Negotiable

No discussion about chainsaws is complete without emphasizing safety. Chainsaws are powerful tools that can cause serious injury if not used properly.

Wear Appropriate Safety Gear: Always wear safety glasses, hearing protection, gloves, chaps, and sturdy boots when operating a chainsaw.
Read the Owner’s Manual: Familiarize yourself with the chainsaw’s operating instructions and safety precautions.
Maintain a Safe Distance: Keep bystanders and pets at least 50 feet away from the cutting area.
Be Aware of Kickback: Kickback is a sudden, uncontrolled upward or backward movement of the chainsaw that can cause serious injury. Be aware of the risk of kickback and take steps to avoid it.
Never Cut Above Shoulder Height: Cutting above shoulder height is dangerous and can lead to loss of control.
Never Cut with One Hand: Always use both hands to operate a chainsaw.
Take Breaks: Chainsaw operation can be tiring. Take frequent breaks to avoid fatigue and maintain focus.
Inspect Your Equipment Regularly: Before each use, inspect your chainsaw for damage and make sure all parts are in good working order.

Budgeting for Your Upsizing Project

Upsizing your chainsaw bar involves some costs. Here’s a breakdown of the typical expenses:

New Chainsaw Bar: Expect to pay between $50 and $150 for a quality bar.
New Chainsaw Chain: A new chain will cost around $30 to $60.
Bar Oil: A gallon of bar oil typically costs around $15 to $25.
Sharpening Tools: If you don’t already have them, you’ll need to invest in a flat file, round file, and file guide, which will cost around $20 to $40.

Resource Management Tip: Consider buying a bar and chain combo to save money. Many retailers offer discounted prices on these bundles.

Case Study: A Small Firewood Producer’s Success

Let’s look at a real-world example of how upsizing can benefit a firewood producer. John, a small-scale firewood producer in rural Maine, was struggling to keep up with demand. He was using an MS291 with a standard 18-inch bar to cut firewood, but he found that he was spending too much time cutting large diameter logs.

After researching his options, John decided to upsize to a 20-inch bar. The results were dramatic. He was able to cut through logs much faster, increasing his productivity by 25%. He also found that the longer bar reduced wear and tear on his chainsaw, saving him money on repairs.

John’s success demonstrates the potential benefits of upsizing for firewood producers and other wood processing professionals.

Next Steps and Additional Resources

You’ve now got a solid understanding of how to upsize your MS291 bar for optimal woodcutting. Here are some next steps you can take:

Research Specific Bar and Chain Options: Dive deeper into specific brands and models of bars and chains that are compatible with your MS291.
Consult with a Chainsaw Expert: Visit your local chainsaw dealer and talk to an expert about your cutting needs.
Practice Your Sharpening Skills: Sharpen your chain regularly to maintain optimal cutting performance.
Join a Chainsaw Forum or Online Community: Connect with other chainsaw enthusiasts and share your experiences.

Additional Resources:

Stihl Website: www.stihl.com
Oregon Products Website: www.oregonproducts.com
Local Chainsaw Dealers: Search online for “chainsaw dealers near me.”
Chainsaw Forums: Search online for “chainsaw forums.”

Concluding Thoughts:

Upsizing your MS291 bar can be a game-changer for your woodcutting efficiency. By carefully considering your needs, choosing the right bar, and following the steps outlined in this guide, you can unlock the full potential of your chainsaw and make your time in the woods more productive and enjoyable. Now get out there and cut some wood! Just remember to be safe and have fun.

MS291 Bar Size Guide: Upsize Tips for Optimal Woodcutting (Pro Hacks)