Why Break Your Own Chains?
Making custom chainsaw chains from Rotatech chainsaw chain compatible 100ft reels is one of the most practical skills for professional arborists and serious DIY enthusiasts. Not only does it reduce costs by 40-50%, but it also allows you to customize chain length precisely for each bar, maximize material from expensive bulk stock, and maintain complete inventory control.
A single 100ft reel typically yields 22-25 complete chains in common sizes (16"-24"), depending on the number of connector links you need to sacrifice during assembly.
Step 1: Gather Your Tools and Materials
Before breaking your first chain, you'll need the proper equipment:
Essential Tools:
- Chain breaker ($30-80): Cuts the chain without damaging individual links
- Rivet spinner ($50-150): Rivets connector links to close the loop
- Connector links (included with reel or purchased separately)
- Safety glasses and work gloves
- Measuring tape
- Flat work surface
Optional but Recommended:
- Vice or C-clamp to hold the reel while breaking
- Wire cutters for cleaning up rivet tails
- File for smoothing rough edges
- Marker for measuring and marking cut points
Step 2: Prepare Your Reel
Unroll your 100ft reel and inspect it for any kinks, damage, or factory defects. Rotatech chainsaw chain compatible reels should arrive in perfect condition, but checking before you begin saves time later.
Coil the reel loosely in manageable sections. Most professionals work with 15-20 foot sections at a time, as this is easier to handle and measure than working with the entire 100 feet at once.
Step 3: Measure Your Chain Length
Accurate measurement is critical to producing chains that fit your bars perfectly. The standard measurement is taken from the centre of the sprocket hole at the end of the bar to the outermost tip of the bar.
Common Bar Lengths and Chain Link Counts:
- 12" bar: 44 links
- 14" bar: 50 links
- 16" bar: 56 links
- 18" bar: 62 links
- 20" bar: 68 links
- 24" bar: 80 links
Calculate based on your bar length and pitch:
- 3/8" pitch chains: Divide bar length (inches) by 0.375 and add 1
- .325" pitch chains: Adjust proportionally
Step 4: Mark and Break the Chain
Using your marker, mark the exact point where you'll break the chain. A 20" bar with 3/8" pitch typically requires 68 individual links from the reel.
Position your chain breaker over the marked rivet:
- Place the chain breaker over the rivet you want to remove
- Tighten the screw slowly until the punch forces the rivet out completely
- Remove the detached link
- Back out the breaker and reposition for the next cut if needed
Pro Tip: Some users prefer leaving one extra link and then using a file to remove the excess rivet material, which can be faster for high-volume breaking.
Rotatech chainsaw chain compatible reels feature consistent rivet sizing, making the breaking process smooth and predictable across the entire length.
Step 5: Create a Ring
After breaking your measured length, you'll have a straight piece of chain with two ends. You now need to connect these two ends to create a closed loop.
Method 1: Using Connector Links (Most Common)
Connector links (also called retaining clips or snap clips) are the easiest way to close a loop:
- Slide the two male ends of your broken chain into the female end of the connector link
- Press firmly until both sides engage fully
- The connector link now holds the chain in a closed loop
This method is reversible and requires no tools, making it excellent for chains you need to replace or modify later.
Step 6: Rivet a Permanent Loop (Optional)
For professional use or chains you want to keep together permanently, riveting creates a more durable closure.
Riveting Process:
- Thread the two ends of your measured chain through a connector link
- Position your rivet spinner over the rivet hole
- Spin the tool counter clockwise firmly but smoothly
- The rivet will gradually deform and lock the connector in place
- Continue spinning until the rivet is fully seated (usually 10-15 rotations)
Rotatech chainsaw chain compatible rivets will deform uniformly, creating a solid joint that matches factory standards.
Warning: Over-riveting can strip the connector link. Stop when you feel firm resistance you're looking for snug, not crushed.
Step 7: Trim and Finish
After riveting, your new chain is mechanically complete, but clean up improves appearance and safety:
- Use wire cutters to trim excess rivet material
- Smooth any rough edges with a file
- Wipe clean with a cloth
- Store in a dry location until use
Step 8: Test the Chain
Before putting your new chain on a saw:
- Check that the chain flexes smoothly through its entire length
- Verify the connector link moves freely with the surrounding links
- Ensure no rivets or connections protrude or bind
- Test that the chain slides easily through a file without snagging
Yield Calculations: Maximizing Your Reel
A well-managed 100ft reel produces excellent value:
- 100 feet total length = 1,200 individual links (at 3/8" pitch)
- 18-link connector per chain × 4 connectors = 72 links lost
- Usable length: 1,128 links
- Chains per reel: 16-20 complete chains (depending on lengths chosen)
Optimizing your breaking strategy—cutting progressively from longest to shortest bar lengths—minimizes waste.
Rotatech Chainsaw Chain: Breaking From Reels
Rotatech chainsaw chain compatible 100ft reels are engineered for easy breaking:
- Consistent rivet spacing for predictable measurements
- Uniform rivet sizing for reliable breaker operation
- Durable link construction that survives the breaking process without deformation
- Compatible connector links available separately
Common Mistakes to Avoid
- Miscounting links: Double-check your link count before breaking
- Forcing the breaker: Let the tool do the work; excessive force damages the rivet
- Misaligned breaking: Position the breaker directly over the rivet centre
- Over-riveting: Stop when you feel solid resistance
- Ignoring wear: Replace chains showing visible damage or dull teeth
When to Buy Pre-Made vs. When to Break Your Own
Break your own if:
- You use 3+ chains monthly
- You have multiple bar lengths
- You have the $150-250 tool investment budget
- You value customization
Buy pre-made if:
- You use fewer than 2 chains monthly
- You only have one bar length
- You value convenience over cost
Top 100ft Chainsaw Chain Reel Brands
Conclusion
Making your own chainsaw chains from Rotatech chainsaw chain compatible 100ft reels is a straightforward, economical skill that pays dividends. With proper tools, accurate measurements, and the techniques outlined here, you can produce professional-quality chains that rival pre-made loops while saving substantial money over time.