When you think about the parts that make up a chainsaw, your mind is most likely drawn to the motor or chain. And, why not? It is the motor that provides power to the chain, which then cuts through materials.
But there’s one other component that is equally as important- a chainsaw bar. This unsung hero is what holds everything together. A high quality bar will help you get through your cutting job with ease. On the other hand, a poorly-designed, worn or damaged bar can make the logging feel like a real chore.
Question is, when do you know it’s time to replace your chainsaw bar? More importantly, what are the best chainsaw bars to buy? In the following guide, we’ve provided answers to these questions and more.
When to Replace your Chainsaw Bar
Regardless of how well you’ve been caring for your chainsaw, a time will come when you’ll have to replace the bar. Here are a few pointers to help you determine the best time for a replacement bar.
Bar Tip Failure
The first thing you should inspect entails the tips of the chainsaw bar.
With prolonged use, the sides of the bar start getting separated, leaving a bit of room in the sprocket.
Once this happens, what’s likely to follow is the chain getting stuck deep into the end of the bar. If you notice this, the best thing to do is to invest in a new chainsaw bar.
Channel Wear
Another problem you are likely to experience if you’ve been using the chainsaw bar for a long time is the wearing out of the channel. If this is the case, you will notice the channel slowly widening. As a result, the chain will flip from one side to the other during use.
The most common culprit of channel wear is excess friction, resulting from the constant movement of the chain around the bar. The good news is, there are a couple of things you can do to slow down the wear such as:
The bad news is that ultimately, the channel will be too worn out, forcing you to get a new chainsaw bar.
Rail Damage
This kind of damage happens in two key places: at the bar’s heel and the nose of the bar. If this happens, you will notice that the rail’s height is never uniform.
To minimize the chances of such damage, be sure to apply the right amount of tension on the chain. Also, remember to flip the guide bar over, on a regular basis.
Guide for Buying a Chainsaw Bar
To a large extent, the type of saw you have will determine the replacement bar you should get. Everything - from the type of chain to the size of the engine- are all factors that will come into play when you’re making this vital decision.
Bar Size
The first thing you should consider when shopping for chainsaw bars is the size of your current one.
So how do you go about measuring your chainsaw bar? Well, it’s a pretty straightforward process as the only thing you need to measure is the useable length of the bar.
This is also known as the called or cutting length. It’s the distance from the tip of the chainsaw bar, going all the way back to the cutter at a point closest to the saw’s body.
Once you get this length, round it to the nearest even number. Let’s say you’ve found the cutting length to be 16 ¾ inches. It means the called length is actually 18 inches. So you’ll be looking for an 18 inch chainsaw bar.
Type of Cutting
Another thing you should keep in mind is that the size of chainsaw bars should be dictated by the type of cutting you do. Here is a brief chart to guide you:
Type of Chainsaw Bars
There are numerous types of chainsaw bars, but the most common are: solid and laminated.
The main difference between these two is the way they’re built. While a solid bar consists of a single piece of steel, a laminated one is constructed by joining two steel rails using a sprocket and steel core.
The design of each bar offers distinct advantages. A solid bar provides more strength, making it the best suited for heavy-duty cutting. On the other hand, a laminated bar offers a higher level of flexibility.
Hard Nose vs Replaceable Tips
Solid chainsaw bars are further divided into those with nose bars or replaceable tips. The latter is the more popular type on the market.
With this replaceable version, the bar will have a sprocket at its tip/nose with rivets and this is where the chain will be positioned. The rivets are meant to hold the chain securely in place, allowing it to turn smoothly.
You might also notice that while the biggest portion of the bar comprises a solid metal, the tip can be detached. This makes it easy to replace in case of any damage.
Hard nose bars are the exact opposite. This is what you expect a solid chainsaw bar to look like, that is, one single metallic piece, which is solid all the way including the tip.
A hard nose bar is the best option if you engage in a lot of rugged cutting jobs. It’s also the most suitable for tasks like cutting fence posts, which require you to use the nose so as to bore directly into the piece of wood.
Engine Capacity
Another factor you should take into account when looking through chainsaw bars is engine capacity. This particularly applies to those who are using gas-powered chainsaws.
The rule of thumb here is that the more powerful the engine, the longer the bar should be. In other words, bigger chainsaw bars are more suited for more powerful saws. This is because more energy is required to drive that chain around a long bar.
Weight
The overall weight of a given chainsaw bar is another factor you should account for.
If it’s too heavy, it will cause you to get fatigued too quickly, especially if you do a lot of cutting. However, if it’s too light, it might not be able to cut through dense materials.
The best chainsaw bar should be able to strike that sweet spot between weight and cutting ability. Be sure to check the weight indicated on its package and read reviews from other buyers to get a feel of how the tool performs.
Pitch
Another thing you need to consider is the type of chain. More specifically, you should focus on its pitch and gauge.
The pitch refers to how far individual links of the chain are from each other. If you look at your chainsaw closely, you’ll notice that both the drive links and cutter links are held securely using rivets.
So to determine the pitch, measure the distance from the center of the first rivet to the center of the third rivet. Next, divide this result by two. Let’s say you’ve measured the distance and found it to be 6/8 of an inch. You’ll divide this by two, to arrive at ⅜ inch as the pitch measurement.
Most chainsaw bars come with a pitch of ⅜ and .325-inch, although you may also find some that have .404-inch.
The general principle here is that the greater the pitch, the more aggressive the cutting performance. For instance, a .404-inch pitch will get through a job faster than a ¼-inch would.
Gauge
Gauge refers to how wide the groove of a chainsaw is, that is, the point where the chain slides into the bar.
There are four common gauge sizes, and you’ll need to determine the size of the current one before purchasing an entirely new bar. The sizes are: .043, .050, .058 and .063.
Ideally, the gauge should be printed on the saw itself or the manual. But if you can’t find it, there’s a trick you can use to determine size. Follow these steps:
Alternatively, you can invest in some precision calipers, which are designed for taking measurements of such elements.
Safety
There's a certain amount of risk that comes with using a chainsaw. To minimize this risk, one of the things you should look for is a bar's kickback tendency.
Kickback is the abrupt uncontrolled movement of a chainsaw. Invest in chainsaw bars equipped with features to reduce kickback. STIHL is a good example of a brand that manufactures professional chainsaw bars with low kickback.
Materials
Also, consider the material used to make a given chainsaw bar.
Remember you’ll be subjecting this tool to a great deal of pressure. Therefore, you want one that can withstand the prolonged abuse without compromising its functionality.
In that regard, the best chainsaw bar will typically be made of high grade steel. Although it might cost more than chainsaw bars made from other materials, it’s worth the investment.
Supplier
Once you have all the specs figured out, the last thing you should think about is where you'll buy your chainsaw bar.
You have two main options: an aftermarket or OEM supplier. OEM means you're sourcing directly from the manufacturer. The latter means you'll be buying from a merchant who deals in a range of other chainsaw parts and from different brands.
The best aftermarket chainsaw bar should look and function in the same way as one bought directly from the manufacturer. Plus, it's much cheaper.
But you'll have to be cautious when choosing a supplier as some sell counterfeit products.
If you don't want to gamble, buying an OEM chainsaw bar is a safer bet. It will likely cost more than similar aftermarket chainsaw bars, but you're guaranteed of the tool's quality and durability.
Top Picks for Best Chainsaw Bars
1. Best Overall: Husqvarna 531300436 HLN250-66 Pixel Chain Saw Bar
This brand is known for the high quality of its equipment so it’s not surprising that Husqvarna chainsaws bars are highly-rated. The HLN250-66 Pixel ChainSaw Bar, in particular, is a fan-favorite and it’s easy to see why. It’s lightweight, sturdy and durable.
Right off the bat, you’ll notice that Husqvarna gives you a wide variety of sizes to pick from. You can choose a 12-, 16-, 18- or 20 inch. However, the model we’re focusing on here is 16-inch with a 0.325-inch pitch and .050-inch gauge.
Tipping the scales at just 1.1 pounds, this bar is pretty light, making it easy to handle. The light weight also contributed to its low vibration operation. However, it doesn’t compromise its functionality. It can get through any cutting job with incredible ease.
Another feature that makes this chainsaw bar stand out is its narrow kerf. The .325-inch pitch narrow kerf mechanism is designed to increase its speed, which makes for a better cutting performance.
As for compatibility, this bar will only work with Husqvarna’s range of chainsaws. More specifically, it fits the 45, 49, 51, 55, 340, 336, 339XP, 345, 351, 346 XP, 350, 353, 445, 435, 440 and 450e.
Pros
Cons
2. Best Chainsaw Bar and Chain Combo: Oregon 39272 Guide Bar
If you’re looking to replace your chain as well, the Oregon 39272 Combo is your best bet. Both the bar and chain are well-built, providing maximum cutting efficiency.
The bar itself, is an 18-inch long, ⅜-inch low-profile gauge. It contains a single rivet and a rather small radius-node. Both of these features help to minimize the saw’s kickback.
But where Oregon chain saw bars really shine is their compatibility. Not only can this bar be paired with electric and gas chainsaws, it also fits a variety of saw brands. Poulan, Echo and Craftsman are just a few of the brands it can work with.
However, keep in mind that it can only work with gas chainsaws up to 42CC.
This chainsaw bar comes equipped with Oregon’s proprietary Lubritec oiling system. The purpose of this is to keep the chain and bar oiled at all times. This, in turn, helps to reduce friction and extend the life of the chainsaw.
Finally, the 39272 uses Oregon’s chamfer chisel cutters, which strike a great balance between cutting performance and consistency.
Pros
Cons
3. Best for Large Chainsaws: Forester Platinum Bar
If you’re looking to replace the guide bar of a really large and powerful saw, then you need one that can keep up with its performance. In that regard, this Platinum model by Forester is a safe bet.
The key highlight of this model is its length. As we mentioned earlier, a more powerful saw requires a longer bar. The Forester comes with a 24 inch bar, making it the longest chainsaw bar and the most suitable for powerful saws.
It sports a ⅜-inch pitch, .050 gauge 84 DL design, perfect for heavy duty cutting jobs. According to the manufacturer, it’s also gone through a recent laser heat treatment to increase the durability of the groove.
The hardness rating of this guide bar is another aspect that makes it suitable for commercial-grade jobs. It scores a remarkable 58 Rockwell hardness, making it a very sturdy piece of equipment.
Pros
Cons
4. Best for STIHL Saws: STIHL 3005 000 4809 Rollomatic E Chain Saw Bar
For all the die-hard fans of STIHL range of saws, the Rollomatic E Chainsaw Bar is one of the best models of guide bars. It’s an OEM part, so you’re guaranteed of it’s durability and reliability.
The most important thing to note about this bar’s design is that it’s laminated. It’s made up of three metal plates of high grade steel, which have been welded together electrically. This results in a highly sturdy and stable chainsaw bar.
Now, you’d probably expect such a tool to weigh a ton. But on the contrary, it weighs just 1.2 pounds, making it one of the lighter models in our review. This, combined with its 14-inch bar length, ⅜-inch pitch, .050-inch gauge and 50 DL design, produces a blade that you can rely on for a long time.
Pros
Cons
5. Best Light Duty: Oregon 105671 Replacement Chainsaw Bar
For light duty cutting jobs, the Oregon 105671 is an excellent replacement bar. Plus, it’s another example of quality chainsaw bars and chain combo, giving you the best value for your money.
One of the things you’ll love about this chainsaw bar is that it delivers exceptional results, thanks to its smooth cutting performance. This is thanks to the Lubritec system, which helps to reduce friction; thus, maximize performance.
The bar is a 20 inch long model with .325-inch pitch and 063-inch gauge.
The only thing lacking in this chainsaw bar is a narrow kerf, which would increase speed. But since it’s only meant for occasional, light-duty work, this is not a big deal.
When it comes to compatibility, it fits an array of Stihl saws, such as Stihl 024, 026, 026P, 028, 029, 030, 031, 032, 034, 036, MS 260, MS 270, MS 271, MS 280 and MS 290.
Pros
Cons
Frequently Asked Questions about Chainsaw Bars
1. Who makes the best chainsaw bar?
Husqvarna is one of the most reputable brands when it comes to power tools, and their chainsaw bars are among the best. They’re durable, reliable, and fairly priced.
2. Are Oregon chainsaw bars any good?
Yes, Oregon chainsaw bars are just as good as those made by Stihl or Husqvarna.
One thing we really love about their tools is that they’re all fitted with the Lubritec system. This works by directing oil to the most essential parts of a guide bar. As a result, there’s very little friction, and this helps to extend the life of your chainsaw bar.
3. What is the best chainsaw bar length?
There’s no specific guide bar length that can be declared to be the best. It all boils down to the thickness of the branch that you’re working with.
A simple trick you can apply is to ensure that the bar length is always 2 inches longer than the material’s thickness. For instance, if your work involves cutting a lot of 8-inch thick branches, then the ideal chainsaw bar should be about 10 inches.
4. Are chainsaw bars universal?
No, they are not. There’s a lot that goes into choosing the perfect bar for your chainsaw, including factors such as size and brand compatibility. As such, you cannot purchase just any bar and expect it to work with your chainsaw.
Wrap Up
When looking for a chainsaw bar replacement, you might be tempted to go for the most expensive option. But you shouldn’t have to pay more than is needed. What you should consider instead is the type of chainsaw you have, and its specifications. Different chainsaws will have different motors, types of chains, cutters and more.
In addition, it’s wise that you purchase this piece of equipment from the best chainsaw bar brand. This way, you have a bit of assurance that you’re buying a high quality chainsaw bar.
That said, one of the best chainsaw bars is Husqvarna HLN250-66 Pixel ChainSaw Bar. Husqvarna chainsaw bars are revered for their cutting-edge performance and this model lives up to the expectation. With a bar length of 16 inches, it boasts several features, such as the narrow kerf that increases cutting speed. It also has low vibration and is light enough to hold for prolonged periods without getting too fatigued.