A little friend of mine asked me to make a chainsaw toy for him. Of course I accepted the challenge!

Here is a list of the tools and materials I used for this project. It took me 45 minutes to finish this project so it is a good project to do along with your kids or grand kids.

Bandsaw
Jointer (optional)
Jig saw
Drill press
20 mm and 28 mm drill bits
Wood glue
Wood (Any species would do, I used pine for this project)
Router (Router table would be better)
Round over router bit
Tape measure
Pencil
Rasp (optional)
Sandpaper (80 and 120 grit)
Wood finish

And here is a video of the building process. Make sure you watch this video first to give you a better idea on how it is made.

Step 1: Cutting the Wood

For this project we will need only four pieces of wood. One for the front chain bar and the rear handle, one for the front handle and one more for the motor case. So cut all the pieces according to the plans provided on this step. Make sure you print the plans full scale.

chainsaw.pdf
Download

Step 2: The Main Part

The main part is actually the front bar and the rear handle in one piece. Cut out the template from the plans and stick it on the piece of wood you have.Drill two holes to start the rear handle. The front hole is 28 mm and the rear 20 mm. Cut the handle with your jig saw and clean it up with a rasp if needed and some sandpaper.

Step 3: The Front Handle

Again cut the piece out of a 2.00 x 8.00 x 12.0 cm piece of wood. Drill two 28mm holes and cut the rest with the jig saw.

Step 4: Round Over

If you want you can use your router with a round over bit to round over all the edges around the pieces.It is optional but recommended to do so.

Step 5: Assembling the Two Pieces Together

Assemble the two pieces together using some wood glue.

Step 6: The Engine Parts

We need to make two more pieces that resemble the engine of the chain saw. Cut them out and shape them on a belt sander or an orbital sander. Glue them behind the front handle as shown on the pictures above.