You’ll need to keep your bar in good shape when using a chainsaw. But at some point, it might begin to curve or bend and cause the saw to run unevenly. This is when you’ll need to learn how to straighten a chainsaw bar.
To straighten a chainsaw bar, start by bending the bar straight with a heavy log. Then lightly beat the bends with a hammer, a rubber mat, or a rubber mallet on a flat surface. Use a clamping device or block for more severe curves and apply pressure to the bend.
In this article, I’ll go over some tried and tested methods and some great strategies you can use at home so that your chainsaw bars are always ready for action whenever you need them.
1. Use a Heavy Log or Plank for Resistance
There are a few steps you should take before using this step.
- First, you should ensure that the chainsaw is unplugged and that the chain is removed.
- Next, you should put on specific protective gear such as gloves and goggles (source).
- Use a plank or heavy log to bend the bar back straight. Hold the bar against the ground while simultaneously applying force to your chosen block.
Make sure you are using enough pressure on the block to make an impact but not so much that you bend the bar too far in the other direction.
2. Use a Heavy Hammer for Large Bends
If the bend is slight, or you need additional strength to reshape the bar while using the above method, you can use a hammer to help reshape the curve.
- The first step is to use a press to get it close.
- Place a heavy-duty rubber pad over the bar so you don’t damage it.
- Use a hammer to pound it to its final shape.
It is essential not to pound around the bar rails when straightening it up, as that will cause them to close up a bit. Once the bar is straight, the rails will be easy to realign.
The best hammer type for this is a heavy one, at least four pounds (1.8 kg). The bar will also need to be resting on a heavy piece of metal or a sheet of metal to keep it stable.
3. A Tractor-Mounted Vertical Wood Splitter
This option is quite extreme, but if you have a piece of equipment like this lying around, it can provide quite an accurate reshaping method.
- Place two Douglas Fir (softwood) end-grain blocks on the anvil, so the bar bend is centered between them.
- Use a flat-sawn block to pad the wedge/ram to straighten a bar.
This is a controlled process because you don’t want to break the bar. You’ll need to keep checking it visually, go a little further, then recheck it until the bar is straight.
When it looks good enough, place the bar on a large shaper tabletop or a flat surface to make sure it does not have any damage to it.
4. Use the Compression of a Workshop Press
A workshop press is a tool that gently but firmly presses the blade back into place without pulling on the chain. It works well for small jobs but can also be used with other tools like vise grips.
It is a simple device that can be used to fix a bent chainsaw bar by aligning the blade. If you have access to a workshop press, follow these tips:
- Place the bent chainsaw bar between two rollers and press down on the rollers to push the metal back into its original shape.
- The key to using a shop press is keeping the pressure on the bar until it is straightened.
- Add force little by little and repeat until the bent chain is straight.
One of the best things about a shop press is that it can be used on any type of chainsaw, regardless of size or complexity. It’s also relatively easy to use, so you should be able to get it done in short order.
5. Everyday Hand Tools
A severely bent chainsaw bar can be straightened using the above methods. It is possible, however, to straighten mild bumps and bends by following a few simple steps with the equipment you might have already lying around:
Tools needed:
- Rubber mallet
- Vise
- Screwdriver
- A flat, stable work table
- Socket set
- Pliers
- Lift the blade guard up, remove the screws or bolts holding the chainsaw’s bar in place, and remove the chain blade.
- Using pliers, pry the bar back into position by placing it in a vise and clamping it firmly in place.
Here’s a video that shows how to remove the chain on a chainsaw:
Remove the bar from the vise, place it flat on a workbench, and tap it with the rubber mallet to help work out the bend. Continue this process until the bar is flat and straight.
How Do I Know if My Chainsaw Should Be Replaced?
Chainsaw bars should be replaced when they start to show signs of wear and tear. These signs include the chain moving from side to side, damaged or jammed bar nose sprockets, titled blade edges, and an unfixable bent or damaged bar.
Since the chainsaw bar revolves around the chain, it is exposed to a lot of heat and resistance. Your chainsaw’s bar will eventually wear out and stop working correctly.
Despite their toughness, chainsaw bars can be challenging to identify when they need to be replaced. Additionally, worn-out bars are difficult to distinguish from good ones. The bar may need to be replaced if it is too bent and challenging to contour (source).
Do you know how you can safely start your chainsaw? Is it safe to start it without a bar and chain? Read my guide to find out.
Final Thoughts
Whether an old chainsaw or a brand new one, you will probably have a few occasions when you find the bar becomes bent. You have a few options if you have a bent bar that needs straightening.
- Heavy log or plank for resistance
- Heavy hammer for large bends
- Tractor-mounted vertical wood splitter
- Workshop press
- Hand tools for mild bends
If you find the bar too bent to be corrected using these methods, you can always take the saw to a repair shop for professional repair.