My circ saw at the mill is dead, What to replace with?

[Brad_bb]

I've had my Bosch Cordless 6.5" circular saw at the mill for a couple years.  I use it to trim a bad spot in a board, or a waney end.  I've been milling Ash on my new property the last 3+ months and I use my cordless saw to cut all the edgings to firewood length in a pile next to the trailer hitch end of the mill.  I do this because then some of the construction guys on site will load it in their vehicle every day or every other day and completely gets rid of the edgings and other bad 2x material.  

Problem is, this week, the clutch in the saw or the motor bearing went bad.  I've always hated this saw because the base lock lever goes below the base when locked, so every time to set the saw down, it unlocks the base.  It's a real pain. Please don't buy this saw!


 

I've seen some with battery powered Stihl chainsaws.  I'm not totally convinced of that option.  It seems great for trimming logs, but how is it on boards?  Boards are much lighter and you can't exactly hold a board with one hand and operate a chainsaw with the other like you can a circ saw.  It looks like the battery chainsaws are much more expensive than a cordless circ saw?

I'm open to other options/recommendations as well.

[Magicman]

I have an 18v Ridgid, but I would not recommend it. 

Never owned one, but I would lean toward a Milwaukee Fuel.

[firefighter ontheside]

I love cordless tools, but I've yet to use a cordless circ saw that impressed me.  I use a stihl or cordless dewalt recip saw.

[trapper]

I am no expert but my Milwaukee Fuel impresed me in a dry 2x12  ash.  Whatever you get decide on a battery system and get all your cordless tools to use that system.

[Don P]

On most saws that lever can be unbolted and repositioned when it wears. I'm not a big fan of cordless circ saws but the fuel is what most of the guys around here like. I put a new armature bearing and brushes in my power planer this week. The bearing locked but when I dug into it the brushes were about done so I just did it all while I was in there. Maybe a couple of hours total, as always the next one would take 15 minutes.

[Dave Shepard]

I have both gen 1 and gen 2 Fuel 7 1/4" saws. The gen 1 didn't like any side bind in quick unguided cuts, but worked well. The Gen 2 is a beast, and will out cut a corded 7 1/4" saw.

[Brad_bb]

I am no expert but my Milwaukee Fuel impresed me in a dry 2x12  ash.  Whatever you get decide on a battery system and get all your cordless tools to use that system.

I have 2 Bosch drills, 2 Bosch impact drivers, and the circ saw and a bunch of batteries and chargers.  I would like to get away from Bosch.  It's just hard to when you have so many tools and batteries.  I lot of timberframers have Makita, but Milwaukee and Dewalt could be options.  I'll have to look into the milwaukee stuff.

[Don P]

Forget the DeWalt!

[doc henderson]

a battery drill/saw is never going to have the power and endurance of a corded saw or tool.  if I am cutting tough or thick hardwood, I run a cord.  it is a compromise.  I have DeWalt and they are ok in my opinion.  I like Makita. Milwaukee, and Bosch tools.  but I think like John Deere they make some cheap homeowner stuff.  I love Porter Cable routers, but now they crank out all kinds of trashy batt. kits.

[Walnut Beast]

Never had any trouble with the Dewalt 18v or the 20v stuff

[barbender]

I've got a dewalt brushless 7 1/4" cordless, and it's pretty impressive. The only way it lags behind a corded saw is it has slightly less torque than my corded saw, so it stalls easier if the blade gets pinched. So I'd say it's not equal to corded, but really close. I haven't plugged my corded one in since I got the cordless, so that says something😊 The only Milwaukee Fuel tool I've got to use, and it was side by side with my Dewalt, was a 4 1/2" grinder. I only had a 4ah battery in my grinder, but that Milwaukee had the edge. Again, I'd say my Dewalt is just about like corded, but not quite. That Milwaukee felt equal to a corded grinder in every way. Oh btw Brad, I have one of the cordless chainsaws as well, the whole reason I got it was because it can be ran with one hand (safely, I think) while holding the work with the other. It's kind of a top handle configuration.

[Walnut Beast]

I've got a dewalt brushless 7 1/4" cordless, and it's pretty impressive. The only way it lags behind a corded saw is it has slightly less torque than my corded saw, so it stalls easier if the blade gets pinched. So I'd say it's not equal to corded, but really close. I haven't plugged my corded one in since I got the cordless, so that says something😊 The only Milwaukee Fuel tool I've got to use, and it was side by side with my Dewalt, was a 4 1/2" grinder. I only had a 4ah battery in my grinder, but that Milwaukee had the edge. Again, I'd say my Dewalt is just about like corded, but not quite. That Milwaukee felt equal to a corded grinder in every way. Oh btw Brad, I have one of the cordless chainsaws as well, the whole reason I did was because it can be ran with one hand (safely, I think) while holding the work with the other. It's kind of a top handle configuration.

Is it 20 v

[Nebraska]

I will vote Milwaukee  cordless as well, you might try their 18volt cordless sawzall, I built most of my sawmill shed with the 18volt  trim saw truth be told, it owes me nothing.  I use a 52 cc efco or dolmar chainsaw for my trim saw on the mill, but the stihl cordless electric would be an option if i had power out to the millshed. 

[Corley5]

Milwaukee Fuel.  Haven't used a corded power tool in a long time.

[Magicman]

Problem is, this week, the clutch in the saw or the motor bearing went bad. I've always hated this saw because the base lock lever goes below the base when locked, so every time to set the saw down, it unlocks the base. It's a real pain. Please don't buy this saw!

As Don P mentioned, loosen the center screw and rotate the locking lever to a suitable position. Since you have so many other Bosch tools and batteries, rebuilding or at least investigating might be the best option.

I have a 40v Ryobi chainsaw that is a beast, but from your description, a circle saw is what you need to continue using.

[longtime lurker]

I hope those construction guys taking the firewood away are either paying or trading beer for it if you're cutting it to length. Otherwise yanno - they owe you for a new saw or they're cutting their own. :D

All my cordless tools are Hitachi and they've been good. Most of my builder customers run either Milwaukee or Hitachi. Doing what you want to do I'd be leaning towards the chainsaw though... a change to how/where you cut will fix the how to hold it problem (put a foot on it) and firewood you can bundle and get a rope or strap around the bundle to hold it together. More expensive for sure but... it will save time and be a better long term option I think.

[barbender]

WB, yes my Dewalt stuff is 20v.

[Bruno of NH]

I run a 60v DeWalt circle saw and chainsaw
Use them both to cut boards
When I worked at the condos 
I was 100% cordless for 6 years.

[terrifictimbersllc]

Recently bought Hilti cordless impact drivers and 5" angle grinder through Home Depot online.  Farmer friend recommended.  Cost a little more than other brands but very impressed with them.  Mine are 22V.  Hilti makes a 7-1/4" 36V circular saw I'd consider if I were in need of a new one.  

Presently have a 28V Milwaukee saw does just fine for my occasional use. 

[Brad_bb]

@longtime lurker , They won't take it if it's not cut to length.  They are helping me keep things clean by getting rid of the stuff.  

I wish I had one of those wrapper machines that would wrap bundles of it.  Then it could be sold locally as kindling/firewood.

I'm gonna think on it- rebuild this one - I think If I sent it to the service center, the cost would be almost as much as a new one.  Go to a new battery system like Milwaukee...   Or spend the money on the electric chainsaw.  I'd like to try one.

[47sawdust]

I bought a Milwaukee 18 volt fuel circular saw 4 years ago.I love it.That being said after 3 years the electronics went on it but it was warranteed by Milwaukee and fixed for nothing.I have since added drill and impact driver,detail saw,reciprocating saw and a string trimmer.
The saw is really sweet,I don't carry many corded tools except for my Bosch contractors saw and my old 1013 Makita sliding compound saw.
No buyer's remorse going red.

[barbender]

Yeah that's another plus with Milwaukee- a 5 year warranty. That's nothing to shake a stick at!

[Walnut Beast]

If you want max power cordless power get 60 volt worm drive 7 1/4 Dewalt

[Walnut Beast]

THE FLEX VOLT DEWALT

20V/60V MAX* FLEXVOLT 9.0 AH BATTERY. the tool automatically adjusts to The Battery you have in

(Admin to the rescue to protect the innocent...)

[Walnut Beast]

Couldn't get it out of that big bold print 😂😂😂

[terrifictimbersllc]

60v print, overloaded the FF. Better check if the administrator is OK   :D

[Don P]

Get the feeling WB is a DeWalt fan? :D
I've actually got a lot of their tools but they can't seem to make a saw I'd like to own. Basically when B&D bought them they moved their industrial line to that brand, and then eroded the quality of both. But that is the nature of biz.

[Woodpecker52]

Have a sears craftsman sawmill brand corded saw, had it 30 years, cuts as good as the day I bought it.  Also use a cheap HF corded saw and I do not baby it one bit and it can take it.

[farmfromkansas]

My old 18 volt Dewalt runs the battery down quickly.  Works a little better in the sawzall, and pretty good on drills.  I had several Dewalt drills when they went to Lithium ion, still have several good nicad batteries.  Have been buying Hitachi now Metabo drills when on sale, but already have one dud battery.  They are 18 volt, and work OK in a drill, can't imagine they have enough power in a circular saw.

[barbender]

You can't compare the power of the old NiCad 18 volt stuff to the new Li-ion 20v brushless tools. The combination of higher amp hour ratings with the brushless technology is a whole different ball game. I have an old 18v Dewalt circular saw (6 1/2") and while it is useful, it doesn't even compare to the newer 7 1/4" brushless saw.

[doc henderson]

half the stuff is prob. made in the same factory, just use a different color plastic for the injection molding.  ;)

[Walnut Beast]

You can't compare the power of the old NiCad 18 volt stuff to the new Li-ion 20v brushless tools. The combination of higher amp hour ratings with the brushless technology is a whole different ball game. I have an old 18v Dewalt circular saw (6 1/2") and while it is useful, it doesn't even compare to the newer 7 1/4" brushless saw.

Your absolutely right. Some of the 18v batteries where a pain to get in and out of various tools at times. ( Dewalt makes a adapter that fits in the 18v to use the 20v battery). The 20v will cut 2x wet treated good for the weight of saw. When you get to the bigger stuff with bigger batteries and multiple batteries the saws are cumbersome and big. Personally I think any good name brand with the lithium ion battery will work fine. You need to see what feels good ergonomically in your hand ,the switch positions for quick one hand control and multiple tool and battery offerings not so much the color of the tool. One of the tools that I have that has been out for several years  that I find amazing still is the oscillating tool. I've put carbide metal blades on and cut nuts off up under a sinks that where so corroded you couldn't get them off any other way. Suburban tire carrier wouldn't come down (made a few cuts).Then fine unusual cuts in wood, metal, plastics and so on 

[SawyerTed]

Another vote for Dewalt 60v Max circular saw.  I've used a Milwaukee and my 60v Max and don't see much difference.  The battery system is what tipped the scale to Dewalt.  I already have drills, impact driver, oscillating saw all from Dewalt. 

Which ever way you choose, keep the battery system compatible.  Tools aren't cheap but batteries are expensive!

[Brad_bb]

Got back home.  I knew had two Bosch 18V circ saws that used the old Ni Cad battery.  Those never lasted long enough to make those saws worth using.  But my idea was, could those saws possibly share the same motor housing with the newer one?

I used to work for Bosch designing Dremel and Rotozip tools.  So I know the intricacies of designing those tools.  If you're changing models, you may not be changing the motor or motor shaft assembly.  If they were just changing battery types, maybe the rest of the tool stayed the same?

Well it turns out the two saws I had at home were the 1662 and the 1664.  My newer Li Ion battery tool is the CCS180.  The motor housing and base of the 1664 looked like they were the same as the CCS180.  The only difference was the battery interface in the handle.


 
So I started to dissassemble the CCS180 handle.  First I had to remove the base locking lever.
Turns out I was wrong in my previous post, you can readjust the position of the locking lever.  Unfortunate I'd been living with that annoyance for so long.  The lever can be clocked in other positions.



I opened the CCS180 handle, which is a neat package with two wires going to the motor.  I clipped those wires close to the motor and removed the lower handle with all the stuff in it.


 
I then opened the 1664 handle.  It was much simpler electronically.  


 
I then removed the handle halves leaving the motor housing with the wires and switch hanging.


 
Then I tried installing the newer handle assembly onto the 1664 motor assembly.  PERFECT FIT!
They hadn't changed the design on the interface of the handle to motor assembly.


 

All I had to do now was clip the motor wires and connect them to the two from the newer handle.  Unfortunately I have all my good Del City Butt connectors down at my other place.  They are heat shrink plastic with a solder ring in the center so when you heat it with the heat gun, It solders and heat shrinks in one step.  I'll have to do that part tomorrow. I put two screws in the other half of the handle to button it up.


 

Now this previous model saw (1664) has the next model handle (CCS180) that uses the newer Li Ion batteries.  Didn't cost me anything As I got those two older tools free when I worked there (they were engineering samples that were going to be thrown out).  Still even if you just found a 1664 on facebook or craigslist or wherever for a low price, you could do the same thing.  

FYI, the 1662 saw was a totally different animal with a smaller motor and housing.  The Li Ion handle would not fit that one.




I'm happy that this will last the rest of this Ash sawing project (another Month or 6 weeks?).  After this, the mill will be near outlets so I'll have more choice as far as using a corded saw or maybe the battery powered chainsaw, which would probably be more useful.  

Also, I will not be buying anymore Bosch tools for this system.  If I need to buy, I'll start looking at Milwaukee's system.

[Wudman]

@Southside has an 80 volt Kobalt Chainsaw at the mill.  It's one of the handiest tools I've ever laid my hands on.  It's very efficient for all around use.  Great tool.  I would recommend it.

Wudman

[Don P]

I picked up a Kobalt drill/driver mainly because the batteries were cheaper. It is fair, looks like I'm losing the drill chuck, the impact is still thumping right along. A buddy went all in and got those, the 1/2" impact which is stronger than my electric, and the saw. Although the saw works, again it wasn't designed by someone who uses a saw, its a contortionist fit. To beat all my wife came up this morning with a Frisbee she bought for the dog and said "can you throw this?" I tried and sure enough, someone designed, produced and marketed a Frisbee that doesn't fly :D I mean really :

[beav]

Brad_bb:
Very impressive solution. You spent a little time, no money, and you are back up running!
I always thought bosch was a top tier tool. Never had one though

[timbur]

I have used the Milwaukee 2732-20 with a 18V 12.0AH Batt in 3 x 12 red oak , it was like cutting a lumberyard 2 x 4 

[bobnic]

Since I got my Dewalt 60v 7-1/4" circular saw last year I have yet to use my plug in circular saw again.  I also have the Dewalt 60v chainsaw which is great for limbing, log trimming, and cutting up slabs but the circular saw is safer and easier to cut boards with.

[moodnacreek]

Clearman or Hurdel. Just kidding.

[esteadle]

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