Shorten a Chainsaw Chain (Expert Tips for Precise Woodcutting)

Aha! I remember the day I realized my chainsaw chain was too long. I was halfway through bucking a massive oak log when the chain started sagging, spitting sawdust everywhere but where it should. It was a frustrating mess, and frankly, a bit dangerous. That day, I learned the hard way the importance of a properly sized chainsaw chain. This guide is born from that experience, and countless others, to help you master the art of shortening a chainsaw chain for precise and safe woodcutting.

Why Shorten a Chainsaw Chain?

There are several reasons why you might need to shorten a chainsaw chain. Understanding these reasons is crucial for proper chainsaw maintenance and optimal performance.

• Chain Stretch: Over time, chainsaw chains stretch due to wear and tear. This stretching can cause the chain to become too loose on the bar, leading to poor cutting performance, increased vibration, and potential derailment.
• Damage: If a section of your chain is damaged (e.g., broken cutters, bent tie straps), removing the damaged links might be the most economical way to salvage the chain rather than replacing the entire thing.
• Incorrect Length: Sometimes, you might accidentally purchase a chain that is slightly longer than required for your chainsaw bar. Shortening the chain to the correct length ensures proper fit and function.
• Bar Modifications: If you’ve modified your chainsaw bar (e.g., by grinding down the tip), you might need to shorten the chain to match the new bar length.

Identifying the Need for Shortening

Before you start cutting links, it’s crucial to accurately determine if your chainsaw chain needs shortening. Here’s how I assess the situation:

• Chain Tension: With the chainsaw turned off and the bar tightened, check the chain tension. A properly tensioned chain should have a slight sag on the underside of the bar, allowing you to pull it away from the bar about 1/8 inch (3mm). If the chain hangs down significantly or feels excessively loose, it likely needs shortening.
• Drive Link Count: Consult your chainsaw’s user manual or the bar itself to determine the correct number of drive links for your specific chainsaw model and bar length. Count the drive links on your chain. If the number exceeds the recommended amount, shortening is necessary. For example, my Stihl MS 271 with a 20-inch bar requires a chain with 72 drive links.
• Visual Inspection: Carefully inspect the chain for signs of damage, such as broken cutters, bent tie straps, or excessive wear. If you find a damaged section, consider removing it to extend the chain’s life. I once had a chain that snagged on a hidden nail, damaging three consecutive cutters. Removing those links saved me from buying a whole new chain.
• Chain Slippage: If your chain frequently slips off the bar, even after proper tensioning, it could be a sign that the chain is too long or excessively worn.

Tools and Materials Required

Shortening a chainsaw chain requires a few specialized tools and materials. Having these on hand will make the process much easier and safer.

• Chain Breaker (Chain Rivet Extractor): This tool is essential for pushing out the rivets that hold the chain links together. A good quality chain breaker will provide leverage and precision, making the job easier and preventing damage to the chain. I prefer a chain breaker with adjustable pins to accommodate different chain sizes.
• Chain Joiner (Chain Rivet Spinner or Peening Tool): After removing the excess links, you’ll need a chain joiner to re-rivet the chain back together. This tool spins the rivet ends, creating a secure and durable connection.
• Bench Vise (Optional but Recommended): A bench vise provides a stable platform for using the chain breaker and chain joiner. It frees up your hands and allows for more precise movements.
• Hammer: A small hammer is needed to tap the chain breaker and chain joiner.
• Punch or Nail Set: A punch or nail set can be helpful for aligning the chain links before re-riveting.
• File or Grinder (Optional): After re-riveting, you might need to file down any sharp edges or burrs on the rivet heads.
• Safety Glasses: Always wear safety glasses when working with tools and metal to protect your eyes from flying debris.
• Gloves: Gloves will protect your hands from sharp edges and potential injuries.
• Chain Repair Links (Optional): If you’re removing a significant number of links, you might need to add a repair link to maintain the correct chain length.

Step-by-Step Guide to Shortening a Chainsaw Chain

Now, let’s get to the actual process of shortening the chain. Follow these steps carefully for a successful outcome.

Step 1: Preparation

• Clean the Chain: Before you start, thoroughly clean the chainsaw chain with a brush and degreaser to remove dirt, sawdust, and oil. This will make it easier to see the links and work with the tools.
• Inspect the Chain: Carefully inspect the chain for any signs of damage, such as cracks, bends, or excessive wear. If the chain is severely damaged, it’s best to replace it rather than attempting to repair it.
• Determine the Number of Links to Remove: As mentioned earlier, count the drive links on your chain and compare it to the recommended number for your chainsaw model and bar length. The difference will tell you how many links to remove. Remember to remove links in pairs (one outer link and one drive link) to maintain the chain’s integrity.
• Mark the Links to be Removed: Use a permanent marker to clearly mark the links you intend to remove. This will help you avoid mistakes and ensure you remove the correct section of the chain.

Step 2: Removing the Links

• Position the Chain in the Chain Breaker: Place the chain in the chain breaker, aligning the rivet you want to remove with the breaker pin. Make sure the chain is securely seated in the tool.
• Apply Pressure to the Rivet: Slowly and steadily apply pressure to the chain breaker handle to push the breaker pin through the rivet. You might need to use a hammer to gently tap the handle if the rivet is particularly stubborn. Be careful not to apply excessive force, as this could damage the chain breaker or the chain.
• Remove the Rivet: Once the rivet is pushed out, carefully remove it from the chain breaker. Repeat this process for the other rivet on the link you want to remove.
• Separate the Chain: After removing both rivets, the chain should separate at the point where you removed the links. Carefully remove the unwanted links from the chain.

Step 3: Rejoining the Chain

• Align the Chain Ends: Bring the two ends of the chain together, ensuring that the drive links are facing in the correct direction. The drive links should point towards the rear of the chainsaw when the chain is installed.
• Insert a New Tie Strap (If Necessary): If you’re using a new tie strap, insert it into the gap between the chain ends. Make sure the tie strap is properly aligned with the other links.
• Position the Chain in the Chain Joiner: Place the chain in the chain joiner, aligning the new tie strap with the joiner pins. Ensure the chain is securely seated in the tool.
• Spin the Rivet Ends: Slowly and steadily turn the chain joiner handle to spin the rivet ends. This will mushroom the rivet ends, creating a secure and durable connection. Apply even pressure to both rivet ends to ensure a balanced connection.
• Check the Connection: After spinning the rivet ends, carefully inspect the connection. The rivet heads should be evenly mushroomed and flush with the surface of the tie strap. There should be no gaps or loose connections.

Step 4: Finishing Touches

• File Down Sharp Edges: Use a file or grinder to smooth down any sharp edges or burrs on the rivet heads. This will prevent the chain from snagging or catching on the bar.
• Lubricate the Chain: Apply a generous amount of chainsaw chain oil to the newly joined section of the chain. This will help lubricate the connection and prevent premature wear.
• Install the Chain on the Chainsaw: Install the shortened chain on your chainsaw, ensuring that the drive links are properly engaged with the sprocket. Tension the chain according to the manufacturer’s instructions.
• Test the Chain: Start the chainsaw and run it at low speed to test the chain. Check for any signs of slippage, vibration, or unusual noise. If everything seems normal, gradually increase the speed and make a few test cuts.

Advanced Tips and Tricks

Over the years, I’ve picked up a few tricks that can make shortening a chainsaw chain even easier and more efficient.

• Use a Bench Vise: As I mentioned earlier, a bench vise is invaluable for holding the chain steady while you’re working on it. This frees up your hands and allows for more precise movements.
• Lubricate the Chain Breaker: Apply a small amount of oil to the breaker pin of the chain breaker to reduce friction and make it easier to push out the rivets.
• Use a Punch for Alignment: If you’re having trouble aligning the chain links before re-riveting, use a punch or nail set to gently tap the links into place.
• Don’t Over-Tighten the Rivets: When spinning the rivet ends, be careful not to over-tighten them. Over-tightening can weaken the connection and cause the chain to break prematurely.
• Check the Chain Tension Frequently: After shortening the chain, check the chain tension frequently during the first few uses. The chain might stretch slightly as it breaks in.
• Keep Your Tools Clean: Clean your chain breaker and chain joiner regularly to remove dirt, sawdust, and metal shavings. This will help ensure that the tools function properly and last longer.

Common Mistakes to Avoid

Shortening a chainsaw chain is a relatively simple process, but it’s easy to make mistakes if you’re not careful. Here are some common mistakes to avoid:

• Removing Too Many Links: Double-check the recommended number of drive links for your chainsaw model and bar length before you start removing links. It’s better to remove too few links than too many.
• Damaging the Chain Breaker: Applying excessive force to the chain breaker can damage the tool or the chain. Use a slow and steady pressure, and don’t be afraid to use a hammer to gently tap the handle.
• Over-Tightening the Rivets: As I mentioned earlier, over-tightening the rivets can weaken the connection and cause the chain to break prematurely.
• Forgetting to Lubricate the Chain: Lubricating the chain after rejoining it is crucial for preventing premature wear and ensuring smooth operation.
• Ignoring Safety Precautions: Always wear safety glasses and gloves when working with tools and metal. Be careful to avoid sharp edges and flying debris.

Troubleshooting Common Problems

Even with the best preparation and technique, you might encounter some problems when shortening a chainsaw chain. Here are some common problems and how to troubleshoot them:

• Difficulty Removing Rivets: If you’re having trouble removing the rivets, try lubricating the chain breaker and applying more pressure. You can also try using a hammer to gently tap the breaker handle. If the rivet is particularly stubborn, it might be damaged or corroded. In this case, you might need to use a different chain breaker or seek professional help.
• Difficulty Rejoining the Chain: If you’re having trouble rejoining the chain, make sure the chain ends are properly aligned and that the drive links are facing in the correct direction. You can also try using a punch or nail set to gently tap the links into place. If the tie strap is damaged or bent, you might need to replace it.
• Chain Breaks at the Joined Section: If the chain breaks at the joined section, it’s likely that the rivets were not properly spun or that the connection was weakened by over-tightening. In this case, you’ll need to remove the broken section of the chain and repeat the rejoining process, being careful to properly spin the rivets and avoid over-tightening.
• Chain Slippage: If the chain slips off the bar after being shortened, it could be a sign that the chain is still too long or that the tension is not properly adjusted. Double-check the chain length and tension, and make sure the drive links are properly engaged with the sprocket.

Chain Maintenance and Longevity

Shortening a chainsaw chain is just one aspect of proper chain maintenance. To ensure your chain lasts as long as possible and performs optimally, follow these additional tips:

• Sharpen the Chain Regularly: A sharp chain is essential for efficient and safe woodcutting. Sharpen your chain regularly using a chainsaw file or a chain grinder.
• Lubricate the Chain Frequently: Keep the chain well-lubricated with chainsaw chain oil. Check the oil level in the chainsaw’s oil reservoir frequently and refill as needed.
• Clean the Chain Regularly: Clean the chain regularly with a brush and degreaser to remove dirt, sawdust, and oil. This will help prevent premature wear and corrosion.
• Store the Chain Properly: When not in use, store the chain in a cool, dry place. Consider coating the chain with oil to prevent rust.
• Inspect the Chain Regularly: Regularly inspect the chain for signs of damage, such as cracks, bends, or excessive wear. Replace the chain if it’s severely damaged.
• Use the Correct Chain for the Job: Use the correct type of chain for the type of wood you’re cutting. For example, use a ripping chain for milling lumber and a standard chain for general woodcutting.

Safety Considerations

Working with chainsaws and chainsaw chains can be dangerous. Always follow these safety precautions to minimize the risk of accidents:

• Wear Appropriate Safety Gear: Always wear safety glasses, gloves, hearing protection, and sturdy footwear when working with chainsaws and chainsaw chains.
• Read the User Manual: Read and understand the user manual for your chainsaw and chain breaker before using them.
• Work in a Safe Environment: Work in a well-lit and well-ventilated area. Keep children and pets away from the work area.
• Disconnect the Spark Plug: Before working on the chainsaw chain, disconnect the spark plug to prevent accidental starting.
• Handle Sharp Objects with Care: Chainsaw chains are very sharp. Handle them with care to avoid cuts and punctures.
• Avoid Overreaching: Avoid overreaching or working in awkward positions. Keep your balance and maintain a firm grip on the chainsaw.
• Be Aware of Kickback: Be aware of the risk of kickback, which can occur when the tip of the chainsaw bar comes into contact with an object. Use proper cutting techniques to minimize the risk of kickback.
• Never Use a Dull Chain: A dull chain is more likely to kick back and can be more difficult to control. Sharpen your chain regularly.
• Seek Professional Help: If you’re not comfortable shortening a chainsaw chain yourself, seek professional help from a qualified chainsaw technician.

Conclusion

Shortening a chainsaw chain is a valuable skill for any woodcutter or chainsaw enthusiast. By following the steps outlined in this guide, you can ensure that your chainsaw chain is properly sized and maintained for optimal performance and safety. Remember to always prioritize safety and to seek professional help if you’re not comfortable performing the task yourself. With a little practice and attention to detail, you’ll be able to keep your chainsaw chain in top condition and enjoy years of efficient and safe woodcutting. Now, go forth and conquer those logs!

Learn more