High Quality Chainsaw Bars Husqvarna Toys

Homemade Reduced Weight Bar

drf256

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I am thinking of doing some weight reduction on some of my longer (32-42") guide bars, and am looking for advice.
I was considering buying a carbide tipped hole saw for taking out some of the mass.

Thoughts on this approach?
IIRC, Treemonkey did a thread on AS about it. I believe he used an endmill and carved out the center section of the bar on both sides, but left some of the middle. Then filled the entire area on both side with JB weld.
 

CR888

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I am no metals406 but I have made some. I used a 61/2" angle grinder and cut off wheel for metal to make cuts parallel to the bar rails. I made much bigger cutouts than the Sugi or Tsumura ones. They could really make their bars much lighter and not saccrifice much strength or rigidness. I then used a 1/4" carbide burr in a die grinder to round off the ends of the cut out sections. My bro is a ship builder and has some two part epoxy or fiberglass resin he will fill the holes with. Go big on the sections Jon don't be worried about strength, I was amazed how solid they turned out after so much stock was removed. I am gonna do a 36" Tsumura next, at this stage I've done a 16" a 20" & 24" in solid Tsumuras and a 18" laminate 'E' bar. Well worth the effort you get a much lighter result than the factory lights. Tree monkey removed one big section I think, I remove 3-6 sections to keep strength. But the tree monkey way would be strong, but maybe not on a 36".
 

Jon1212

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I am no metals406 but I have made some. I used a 61/2" angle grinder and cut off wheel for metal to make cuts parallel to the bar rails. I made much bigger cutouts than the Sugi or Tsumura ones. They could really make their bars much lighter and not saccrifice much strength or rigidness. I then used a 1/4" carbide burr in a die grinder to round off the ends of the cut out sections. My bro is a ship builder and has some two part epoxy or fiberglass resin he will fill the holes with. Go big on the sections Jon don't be worried about strength, I was amazed how solid they turned out after so much stock was removed. I am gonna do a 36" Tsumura next, at this stage I've done a 16" a 20" & 24" in solid Tsumuras and a 18" laminate 'E' bar. Well worth the effort you get a much lighter result than the factory lights. Tree monkey removed one big section I think, I remove 3-6 sections to keep strength. But the tree monkey way would be strong, but maybe not on a 36".

Did you finish the outside edge of the cutout section at 45° from both sides of the bar?
 

USMC615

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DSS

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Jon1212

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What specific diameter annular, carbide-tipped or HSS (high speed steel) cutters are you interested in?
Probably somewhere around 1"(25mm). My thought was to cut the holes as the ends of two long sided ovals. Basically two shorter versions of the cutout in an Oregon RW bar.
 

huskihl

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Probably somewhere around 1"(25mm). My thought was to cut the holes as the ends of two long sided ovals. Basically two shorter versions of the cutout in an Oregon RW bar.
Chop chop, guinea pig. I gots a 36" GB bar that drags in the snow
 

Brush Ape

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