Do-it-yourself lightweight pocket chainsaw

Paracord has been used for parachutes since World War II.  You do not need very much of it to make this project, but since it has great tensile strength, you can easily get about 25 feet of paracord (and in several different colors) for around $8.00 (shop around to find the cheapest place to purchase this item).  Refrain from substituting nylon rope and especially hemp rope unless you are prepared to replace it often. Cut two lengths of paracord about 1 foot long.  This length will be shortened a bit at the ends once you tie the knots to secure them to the chainsaw blade and the carabiners.Put one end of your paracord through the hole in the chainsaw blade that you drilled and tie it off with a bow line knot (see illustration).  On the other end of that piece of paracord, tie another bow line knot to the first carabiner.  Repeat the process for the other end of the chainsaw blade with your other piece of paracord.  Tie your last bow line knot onto the second carabiner.  Make sure all of the knots are as tight as possible.After you've cut your chainsaw blade, you want to drill holes through the rivet that holds the very last blade section together.  It should be the very last rivet on each end of your chain.Use a drill bit that can not only get through tough metal, but gauge the size of your bit so that the paracord (see next steps) can fit through that hole.  Use a small file or steel wool, if necessary, to make sure that the drilled hole does not have rough edges inside it.The first part of making a pocket chainsaw is, of course, the blade.  Many people who try this project often cut the chainsaw blade in the wrong location.  The ideal location for cutting the blade, if it isn't already broken or cut, is between the solid (see photo) area where two blade sections are held together, not at the knuckle where the blade sections rotate.Use a hacksaw, handsaw or power saw that can cut through metal.  Use eye protection as you cut.  Work gloves are also recommended as the blade teeth and cut ends can be sharp.  Optionally, you can use a bolt cutter to make the necessary cut, but do so in the same area on the blade as shown in the photo.You want to make sure you are leaving both ends (in photo the left side of the "cut here" line) of your pocket chainsaw blade without a blade tooth. If you are using an already broken chainsaw blade, you should take the last two blade sections off to make sure you have a good end on each side for your pocket chainsaw.The length of the entire chain is up to you, but at least 2 feet is highly recommended.  It depends on what size (diameter) tree, logs or metal you are going to have to cut, but with the added length of your handles (see the rest of the instructions), a longer chain can not only make it heavier to carry, but difficult to find a pouch or can to store it in. View the list »
What you'll need to make the pocket chainsaw:a chainsaw replacement blade or used chainsaw bladea hacksaw with a blade that cuts metal an electric drill with drill bit2 locking carabiners1 length of paracord  (see instructions for length)1 small bottle of gorilla glue/super glue that bonds to metal and rubber (optional)1 medium piece of garden hose (optional)1 bolt cutter (optional)1 small file or steel wool One way to find already broken, used chainsaw blades is to visit a neighbor who has a chainsaw, or to go to a chainsaw repair store and ask if you can have one of the used chains.  This will save you the cost of purchasing a brand new replacement chain saw blade.  The blade does not have to be a large one with big teeth to be effective.  In fact, many people prefer a bit smaller teeth size for a pocket chainsaw.  The blade should be rust-free.  If it isn't, soak the chain in a rust-removing product like WD-40 overnight and use a wire brush to clean the blade.  Keeping the blade oiled will also preserve the lifetime of your blade, especially when it is not in use.An electric drill is recommended for this project mainly because you do not want to have to rely on a batter-powered one, unless it is fueled by lithium batteries (fully charged).  To drill through the chain, it will take some "juice".For this project, the list of materials includes several optional items.  As you read the remainder of the how-to, I will illustrate where those optional items may be used.Remember, this project is meant to be economical.  And, above all, fun.    

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Pocket chainsaws have been something that the U.S. military and campers have been using for quite awhile. They are lightweight, use manual power and can cut through smaller trees very quickly. They can be stored in a small can (ie. tobacco can) with a lid, or even a pouch. When out in the back-country, a pocket chainsaw can help you create firewood. Some have even used these handy tools to cut through metal.

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In this instructional guide, I will show you how to make a variation of a pocket chainsaw, using a regular chainsaw blade, that is both economical and should help you with your sustainable life.

(See the list for building instructions and materials list)

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  • What you'll need to make the pocket chainsaw:a chainsaw replacement blade or used chainsaw bladea hacksaw with a blade that cuts metal an electric drill with drill bit2 locking carabiners1 length of paracord  (see instructions for length)1 small bottle of gorilla glue/super glue that bonds to metal and rubber (optional)1 medium piece of garden hose (optional)1 bolt cutter (optional)1 small file or steel wool One way to find already broken, used chainsaw blades is to visit a neighbor who has a chainsaw, or to go to a chainsaw repair store and ask if you can have one of the used chains.  This will save you the cost of purchasing a brand new replacement chain saw blade.  The blade does not have to be a large one with big teeth to be effective.  In fact, many people prefer a bit smaller teeth size for a pocket chainsaw.  The blade should be rust-free.  If it isn't, soak the chain in a rust-removing product like WD-40 overnight and use a wire brush to clean the blade.  Keeping the blade oiled will also preserve the lifetime of your blade, especially when it is not in use.An electric drill is recommended for this project mainly because you do not want to have to rely on a batter-powered one, unless it is fueled by lithium batteries (fully charged).  To drill through the chain, it will take some "juice".For this project, the list of materials includes several optional items.  As you read the remainder of the how-to, I will illustrate where those optional items may be used.Remember, this project is meant to be economical.  And, above all, fun.    
  • The first part of making a pocket chainsaw is, of course, the blade.  Many people who try this project often cut the chainsaw blade in the wrong location.  The ideal location for cutting the blade, if it isn't already broken or cut, is between the solid (see photo) area where two blade sections are held together, not at the knuckle where the blade sections rotate.Use a hacksaw, handsaw or power saw that can cut through metal.  Use eye protection as you cut.  Work gloves are also recommended as the blade teeth and cut ends can be sharp.  Optionally, you can use a bolt cutter to make the necessary cut, but do so in the same area on the blade as shown in the photo.You want to make sure you are leaving both ends (in photo the left side of the "cut here" line) of your pocket chainsaw blade without a blade tooth. If you are using an already broken chainsaw blade, you should take the last two blade sections off to make sure you have a good end on each side for your pocket chainsaw.The length of the entire chain is up to you, but at least 2 feet is highly recommended.  It depends on what size (diameter) tree, logs or metal you are going to have to cut, but with the added length of your handles (see the rest of the instructions), a longer chain can not only make it heavier to carry, but difficult to find a pouch or can to store it in. 
  • After you've cut your chainsaw blade, you want to drill holes through the rivet that holds the very last blade section together.  It should be the very last rivet on each end of your chain.Use a drill bit that can not only get through tough metal, but gauge the size of your bit so that the paracord (see next steps) can fit through that hole.  Use a small file or steel wool, if necessary, to make sure that the drilled hole does not have rough edges inside it.
  • Paracord has been used for parachutes since World War II.  You do not need very much of it to make this project, but since it has great tensile strength, you can easily get about 25 feet of paracord (and in several different colors) for around $8.00 (shop around to find the cheapest place to purchase this item).  Refrain from substituting nylon rope and especially hemp rope unless you are prepared to replace it often. Cut two lengths of paracord about 1 foot long.  This length will be shortened a bit at the ends once you tie the knots to secure them to the chainsaw blade and the carabiners.Put one end of your paracord through the hole in the chainsaw blade that you drilled and tie it off with a bow line knot (see illustration).  On the other end of that piece of paracord, tie another bow line knot to the first carabiner.  Repeat the process for the other end of the chainsaw blade with your other piece of paracord.  Tie your last bow line knot onto the second carabiner.  Make sure all of the knots are as tight as possible.
  • In this example (see photo) you can see there are different ways to knot paracord, or even braid it, to make it stronger or just visually appealing. For this project, do not use the type of carabiner shown at the top of the photo.  Make sure you use a locking carabiner (the screw together ones work best on the locking side - see bottom example on photo).  You don't want to be cutting and have your paracord handles escape and cause an accident. Here is where your options come in, especially with the garden hose.The locking carabiners at the ends of your new pocket chainsaw will be the handles you use to pull back and forth to make the saw work as you cut through trees, logs, or even metal (yes, metal).  Some who have used similar products purchased from camping supply stores complain that the metal rings (here, I have replace flimsy wire with thicker metal in carabiners) give them severe blisters on their fingers and/or hands.To prevent this, or to simply get a better grip, take a bit of used garden hose and cut it slightly shorter than the length of the flat side of the carabiner.  You can cut the hose with a box cutter/utility knife or your hacksaw.  Use a metal-bonding and rubber-bonding all-purpose glue, like Gorilla glue, to keep the piece of hose in place on the carabiner.  Use gloves of some sort when applying the glue - some is very hard to remove from your hands and can even cause burns. The garden hose cover will also help if you are using your pocket chainsaw in the cold.  The metal carabiner won't be as prone to freezing your hand/fingers.Alternately, rubber hosing can be used, but garden hoses are meant to contract and expand and last longer.  Rubber hose can get brittle, especially when exposed to sunlight or the elements.  Experiment if you think you have a better idea. Some have use braided paracord to cover the flat side (pulling side of the handle/carabiner), but this can cause rope burns.Be creative and use this as an example.  The design I have shown you will cut through a 4- to 5-inch diameter tree trunk or log in under a minute, depending on how fast you pull back and forth.
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Christina Rivers is a freelance journalist and photographer that was raised in a family that promoted frugal, self-sustaining life methods. Covering everything from home food storage and personal preparedness to emergency survival and medicine, Christina offers readers an opportunity to create...

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