Poulan Pro PR5020 Bar and Chain: Using a 24″ Bar? (Expert Tips)

Ignoring the limitations of your chainsaw bar is a shortcut to disaster. Let’s explore safely using a 24″ bar on your Poulan Pro PR5020.

Understanding Chainsaw Bar and Chain Compatibility

Before even considering slapping a 24-inch bar on your Poulan Pro PR5020, it’s crucial to understand the fundamentals of chainsaw bar and chain compatibility. It’s not just about length; it’s about power, chain pitch, gauge, and overall balance.

Key Concepts:

• Bar Length: The usable cutting length of the bar, measured from the chainsaw body to the tip. Longer bars allow for cutting larger diameter trees, but they also require more power.
• Chain Pitch: The distance between three consecutive rivets on the chain, divided by two. Common pitches are .325″, 3/8″, and .404″. The chainsaw’s drive sprocket must match the chain pitch.
• Chain Gauge: The thickness of the drive links that fit into the bar’s groove. Common gauges are .043″, .050″, .058″, and .063″. The bar groove width must match the chain gauge.
• Drive Links: The number of drive links on the chain. This number is specific to the bar length and the chainsaw model.
• Engine Power: Chainsaws are designed with specific engine power outputs. A longer bar requires more power to pull the chain through the wood efficiently.
• Kickback: The sudden, uncontrolled movement of the chainsaw bar, often occurring when the tip of the bar contacts an object. Longer bars increase the risk of kickback.

The Poulan Pro PR5020: What You Need To Know

The Poulan Pro PR5020 is typically sold with a 20-inch bar. It’s a decent saw for homeowners and light-duty tasks. However, it’s not a professional-grade logging saw. The engine displacement and horsepower are designed to work optimally with a 20-inch bar.

• Engine Displacement: Usually around 50cc.
• Horsepower: Typically between 2.5 and 3 horsepower.

Important Note: Trying to force a longer bar on a saw that isn’t designed for it will lead to:

• Reduced Cutting Performance: The saw will bog down, and cutting will be slow and inefficient.
• Increased Wear and Tear: The engine and other components will be stressed, leading to premature failure.
• Increased Risk of Kickback: The saw will be more difficult to control, increasing the risk of kickback and injury.

Can You Really Use a 24-Inch Bar on a Poulan Pro PR5020?

Technically, yes, you can physically mount a 24-inch bar on a Poulan Pro PR5020, if you find a bar with the correct mount pattern, chain pitch, and gauge. However, just because you can doesn’t mean you should.

Here’s the crucial question: Does the PR5020 have enough power to effectively and safely pull a 24-inch chain through wood? In most cases, no.

My Personal Experience:

I’ve seen countless homeowners try to “upgrade” their chainsaws with longer bars, thinking it will make them more productive. In almost every case, it backfires. They end up with a saw that’s difficult to control, bogs down constantly, and ultimately leads to frustration and potentially dangerous situations. I once helped a neighbor who insisted on putting a 24-inch bar on a similar 50cc saw. He spent the entire afternoon struggling to cut a single oak log, and the saw overheated multiple times. In the end, he gave up and admitted he should have listened to me.

Factors to Consider Before Upgrading:

• Wood Type: Cutting softwoods like pine is easier than cutting hardwoods like oak or maple. If you’re only cutting small diameter softwoods, a 24-inch bar might be manageable, but still not optimal.
• Cutting Frequency: If you’re only cutting occasionally, you might be willing to tolerate the reduced performance. However, if you’re cutting regularly, the strain on the saw will shorten its lifespan.
• Your Skill Level: If you’re an experienced chainsaw user, you might be able to compensate for the lack of power with careful technique. However, if you’re a beginner, using a 24-inch bar on a PR5020 is a recipe for disaster.

Step-by-Step Guide (If You Still Insist on Trying)

If, after considering all the warnings, you’re still determined to try using a 24-inch bar on your Poulan Pro PR5020, follow these steps carefully. Remember, safety is paramount.

Step 1: Verify Bar and Chain Compatibility

This is the most crucial step. You need to ensure that the bar and chain are compatible with your chainsaw and each other.

• Mount Pattern: The bar must have the correct mount pattern to fit the PR5020’s bar studs. Consult your owner’s manual or a chainsaw parts website to determine the correct mount pattern.
• Chain Pitch: Determine the chain pitch of your PR5020 (likely .325″ or 3/8″). The new chain must have the same pitch.
• Chain Gauge: Determine the chain gauge of your PR5020 (likely .050″ or .058″). The new chain must have the same gauge.
• Drive Links: Calculate the number of drive links required for a 24-inch bar on your PR5020. This information is usually available on chainsaw parts websites or from the bar manufacturer.
• Oiler Compatibility: Verify that your chainsaw’s oiler can adequately lubricate a 24-inch bar. Longer bars require more oil.

Example:

Let’s say your Poulan Pro PR5020 uses a .325″ pitch, .050″ gauge chain, and you’ve determined that a 24-inch bar requires 84 drive links. You would need to purchase a 24-inch bar with the correct mount pattern and a chain with .325″ pitch, .050″ gauge, and 84 drive links.

Step 2: Purchase the Correct Bar and Chain

Once you’ve verified compatibility, purchase the bar and chain from a reputable supplier. Avoid cheap, generic bars and chains, as they are often made from inferior materials and can be dangerous.

Recommended Brands:

• Oregon: A well-known and respected brand for chainsaw bars and chains.
• Stihl: Another high-quality brand, although their bars and chains can be more expensive.
• Husqvarna: Similar to Stihl, Husqvarna offers high-quality products.

Step 3: Install the Bar and Chain

1. Remove the existing bar and chain: Follow the instructions in your owner’s manual to safely remove the existing bar and chain.
2. Inspect the sprocket: Check the drive sprocket for wear and tear. If it’s worn, replace it.
3. Mount the new bar: Place the new bar onto the bar studs, ensuring that it’s seated correctly.
4. Install the new chain: Drape the chain around the sprocket and into the bar groove. Make sure the cutting edges of the chain are facing the correct direction (they should point forward at the top of the bar).
5. Adjust the chain tension: Use the chain tensioning screw to adjust the chain tension. The chain should be snug but still able to be pulled around the bar by hand.
6. Tighten the bar nuts: Tighten the bar nuts securely.

Step 4: Test the Chainsaw

Before using the chainsaw, test it to ensure that it’s running properly.

1. Start the chainsaw: Start the chainsaw according to the instructions in your owner’s manual.
2. Check the chain oiler: Verify that the chain oiler is working properly. The chain should be coated with oil as it runs.
3. Make a test cut: Make a small test cut in a piece of softwood. Observe how the chainsaw performs. Does it bog down easily? Is it difficult to control?

Step 5: Adjust Your Cutting Technique

If you’re using a 24-inch bar on a PR5020, you’ll need to adjust your cutting technique to compensate for the lack of power.

• Take smaller bites: Don’t try to force the saw through the wood. Let the chain do the work.
• Use the weight of the saw: Let the weight of the saw help you cut. Don’t push down on the bar.
• Keep the chain sharp: A sharp chain is essential for efficient cutting. Sharpen the chain frequently.
• Avoid pinching: Be careful to avoid pinching the bar in the cut. Use wedges to keep the cut open if necessary.

Safety Considerations

Using a 24-inch bar on a Poulan Pro PR5020 significantly increases the risk of accidents. Always follow these safety precautions:

• Wear appropriate safety gear: This includes a helmet with a face shield, hearing protection, gloves, chaps, and steel-toed boots.
• Be aware of kickback: Kickback is a common cause of chainsaw injuries. Be especially careful when cutting near the tip of the bar.
• Maintain a safe working distance: Keep bystanders at least twice the length of the bar away from the cutting area.
• Never cut above your head: Cutting above your head is extremely dangerous.
• Never cut with a dull chain: A dull chain is more likely to kick back.
• Never cut in wet or icy conditions: Wet or icy conditions can make it difficult to control the chainsaw.
• Never cut under the influence of drugs or alcohol: This should be obvious.
• Read and understand your owner’s manual: Your owner’s manual contains important safety information.

Case Study: The Overzealous Homeowner

I once encountered a homeowner who was determined to fell a large oak tree in his backyard using a Poulan Pro PR5020 with a 24-inch bar. He had no experience with felling trees, and he ignored all my warnings about safety. He started cutting into the tree without making a proper notch, and the tree started to fall in the wrong direction. He panicked and tried to run, but he tripped and fell. The tree narrowly missed him, but it crushed his shed. He was lucky to be alive. This incident highlights the importance of safety and experience when using a chainsaw.

Alternatives to Using a Longer Bar

If you need to cut larger diameter trees, there are safer and more effective alternatives to using a longer bar on your Poulan Pro PR5020:

• Rent a larger chainsaw: Renting a larger chainsaw with a more powerful engine and a longer bar is a much safer and more efficient option.
• Hire a professional: Hiring a professional tree service is the safest option, especially for felling large trees.
• Use a different tool: For smaller diameter logs, consider using a handsaw or a bow saw.

Chainsaw Maintenance Tips

Regardless of the bar length you’re using, regular chainsaw maintenance is essential for safe and efficient operation.

• Sharpen the chain regularly: A sharp chain is essential for efficient cutting and reducing the risk of kickback. Use a chainsaw file or a chain grinder to sharpen the chain.
• Clean the air filter: A dirty air filter can restrict airflow to the engine, reducing performance. Clean the air filter regularly with compressed air or soap and water.
• Clean the bar groove: The bar groove can become clogged with sawdust and debris, preventing the chain from running smoothly. Clean the bar groove regularly with a screwdriver or a bar groove cleaner.
• Check the spark plug: A fouled spark plug can cause the engine to run poorly or not start at all. Check the spark plug regularly and replace it if necessary.
• Lubricate the bar and chain: Proper lubrication is essential for reducing wear and tear on the bar and chain. Use a high-quality bar and chain oil.
• Store the chainsaw properly: When not in use, store the chainsaw in a dry place. Drain the fuel tank and remove the bar and chain.

Understanding Wood Types and Their Impact

The type of wood you’re cutting significantly impacts the chainsaw’s performance, especially when pushing the limits with a longer bar.

Green Wood vs. Seasoned Wood

• Green Wood: Wood that has been recently cut and still contains a high moisture content. Green wood is heavier, more difficult to split, and puts more strain on the chainsaw.
• Seasoned Wood: Wood that has been allowed to dry for several months or years, reducing its moisture content. Seasoned wood is lighter, easier to split, and puts less strain on the chainsaw.

Cutting green wood with a 24-inch bar on a PR5020 will be significantly more difficult than cutting seasoned wood. The higher moisture content increases friction and requires more power to cut through.

Hardwood vs. Softwood

• Hardwood: Wood from deciduous trees, such as oak, maple, and ash. Hardwoods are denser and more difficult to cut than softwoods.
• Softwood: Wood from coniferous trees, such as pine, fir, and spruce. Softwoods are less dense and easier to cut than hardwoods.

Cutting hardwoods with a 24-inch bar on a PR5020 will be much more challenging than cutting softwoods. The higher density of hardwoods requires more power to cut through.

Example:

Trying to cut a large diameter oak log that is still green with a 24-inch bar on a PR5020 is a recipe for frustration and potential damage to the chainsaw. On the other hand, cutting a smaller diameter pine log that is seasoned might be manageable, but still not optimal.

Strategic Considerations for Wood Processing

Beyond just cutting, consider the overall strategy for wood processing. Are you preparing firewood? Felling trees for lumber? The intended use of the wood will influence your choice of tools and techniques.

Firewood Preparation

• Felling: Felling trees safely and efficiently requires proper technique and experience.
• Bucking: Cutting logs into manageable lengths for splitting.
• Splitting: Splitting logs into smaller pieces for burning.
• Stacking: Stacking firewood properly to allow for air circulation and drying.
• Drying: Allowing firewood to dry for several months or years to reduce its moisture content.

My Firewood Stacking Method:

I prefer to stack my firewood in single rows, with each row slightly offset from the row below. This allows for maximum air circulation and promotes faster drying. I also cover the top of the stack with a tarp to protect it from rain and snow, but I leave the sides open to allow for ventilation.

Lumber Production

• Felling: Felling trees safely and efficiently requires proper technique and experience.
• Debarking: Removing the bark from the logs to prevent insect infestation and promote drying.
• Milling: Cutting the logs into lumber using a sawmill.
• Drying: Drying the lumber to reduce its moisture content and prevent warping.
• Planing: Smoothing the surface of the lumber.

Log Splitters: A Valuable Tool for Firewood Preparation

If you’re preparing firewood regularly, a log splitter can be a valuable tool. Log splitters come in two main types:

• Manual Log Splitters: These splitters use a lever or foot pedal to force the log against a wedge. They are relatively inexpensive but require significant physical effort.
• Hydraulic Log Splitters: These splitters use a hydraulic pump to force the log against a wedge. They are more expensive but require less physical effort.

Why I Recommend a Hydraulic Log Splitter:

While manual log splitters are cheaper, the physical strain involved can be significant, especially when splitting large quantities of wood. A hydraulic log splitter significantly reduces the effort required, allowing you to split more wood in less time and with less fatigue.

Case Study: The Efficient Firewood Processor

I know a small-scale firewood business owner who uses a hydraulic log splitter to prepare firewood for sale. He can split several cords of wood per day with minimal effort. He also uses a conveyor belt to move the split wood into piles, further increasing his efficiency.

Measurements, Tool Specifications, and Wood Type Selections

Here are some specific measurements, tool specifications, and wood type selections to consider:

• Chainsaw Bar Length: Choose a bar length that is appropriate for the size of the trees you will be cutting. A 20-inch bar is generally sufficient for most homeowners, while professional loggers may need longer bars.
• Chainsaw Engine Displacement: Choose an engine displacement that is appropriate for the size of the bar you will be using. A 50cc engine is generally sufficient for a 20-inch bar, while longer bars require more powerful engines.
• Axe Weight: Choose an axe weight that is comfortable for you to swing. A 6-pound axe is a good all-around choice.
• Log Splitter Tonnage: Choose a log splitter tonnage that is appropriate for the size of the logs you will be splitting. A 20-ton log splitter is generally sufficient for most homeowners.
• Wood Moisture Content: Aim for a moisture content of 20% or less for firewood. Use a moisture meter to check the moisture content of the wood.
• Wood Drying Time: Allow firewood to dry for at least six months, and preferably a year or more.

Cost, Material Specs, Timing Estimates, and Skill Levels

• Cost: The cost of wood processing and firewood preparation can vary widely depending on the tools and equipment you use. A basic setup, including a chainsaw, axe, and safety gear, can cost several hundred dollars. A more advanced setup, including a log splitter and conveyor belt, can cost several thousand dollars.
• Material Specs: Choose high-quality tools and equipment that are designed to withstand the rigors of wood processing. Look for tools made from durable materials such as steel and aluminum.
• Timing Estimates: The time required for wood processing and firewood preparation can vary widely depending on the size and type of wood you are working with. Felling a tree can take anywhere from a few minutes to several hours, while splitting a cord of wood can take several hours or even days.
• Skill Levels: Wood processing and firewood preparation require a range of skills, from basic chainsaw operation to advanced felling techniques. Start with simple tasks and gradually work your way up to more complex tasks as you gain experience.

Next Steps

If you’re ready to start your own wood processing or firewood preparation project, here are some practical next steps:

1. Assess your needs: Determine what type of wood processing or firewood preparation you want to do.
2. Gather your tools and equipment: Purchase or rent the necessary tools and equipment.
3. Learn the basics: Read books, watch videos, or take a class on wood processing and firewood preparation.
4. Practice safely: Start with simple tasks and gradually work your way up to more complex tasks.
5. Be patient: Wood processing and firewood preparation take time and effort. Don’t get discouraged if you don’t see results immediately.

Conclusion

While technically possible, using a 24-inch bar on a Poulan Pro PR5020 is generally not recommended due to the saw’s limited power. It can lead to reduced performance, increased wear and tear, and a higher risk of accidents. If you need to cut larger diameter trees, consider renting a larger chainsaw or hiring a professional. Always prioritize safety and follow the manufacturer’s instructions. Remember that understanding your tools, wood types, and safe practices is the key to successful and enjoyable wood processing.

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