Best Commercial Battery Backpack Blower

The Tool Box Buzz Crew seeks to crown the best commercial-grade battery backpack blower in this most recent Head-to-Head comparison test. In 2023 our crew tested and chose the best Handheld Cordless Blower. Building on that success, we are now examining battery backpack blowers. However, this Head-to-Head will primarily be geared towards commercial users. Backpack blowers are synonymous with the landscaping and property maintenance trades. We aim to determine which blowers are ready to keep up with demanding commercial use and provide the best options for pros looking to purchase a battery-powered model.

Are Battery Blowers Ready for Prime-time?

The demand for rugged, commercial-grade, battery-powered OPE is constantly growing. This demand is being fueled by technological improvements as well as legislative requirements. As of June 2024, more than one hundred cities in the United States, and the entire state of California, have banned or restricted the use of gas-powered leaf blowers. Contractors are now forced to look for battery-powered options to stay in business. These restrictions have forced OPE companies to step up their game.

Direct Comparison to Gas Powered

One common question with all battery OPE is how the tools perform compared to traditional gas-powered models. While gas vs. battery is not a true even comparison, we elected to include a gas-powered model in some of our testing to provide an additional data point. The gas-powered model will not be included in any of our rankings, but we felt the information collected is of interest.

Echo provided a sample of their model PB-770T X Series backpack blower. This blower features a 63.3 CC professional-grade two-stroke engine. This is Echo’s smallest commercial-grade backpack blower and is a close comparison to our battery-powered options in terms of power and output. Its technical specifications are as follows:

• Max Air Volume: 756 CFM
• Max Air Speed: 234 MPH
• Max Blowing Force: 33
• Fuel Capacity: 68.3 Fl./Ozs.
• Warranty: 2 Year Commercial

Best Commercial Battery Backpack Blower  | Test Criteria

We selected eight categories to determine our best commercial battery backpack blower of 2024. The tools were ranked in each category and an overall score was later used to determine our winner. The evaluation categories are:

• Measured Maximum Air Speed (MPH)
• Calculated Maximum Air Volume (CFM)
• Total Run-time on a Battery Charge (Minutes)
• Power Sled Performance Test
• Measured Noise Output (Decibels)
• Assembled Weight
• Features and Ergonomics
• Price

In addition to our overall winner, we selected a tool as our Best Value. This category highlights a single backpack blower that may not be our top-performing tool but offers an excellent overall value based on its features and performance compared to its price.

Battery Backpack Blower Lineup

Once our testing criteria were finalized, we identified the current available pro-grade models. Invitations were sent to the manufacturers to participate in our Head-To-Head. A total of six companies agreed to participate and provided us with samples of their products. Not every company that was invited chose to participate however our sample size is an excellent representation of the pro-user market.

Our participating companies provided us with the backpack blower unit, a battery, and a charger. Additionally, manufacturers were invited to include any accessories or optional parts that improve the overall user experience. Only one company elected to do this. Stihl provided us with an upgraded waist belt to enhance user comfort.

Echo eFORCE

• Model: DPB-5800T
• Battery Platform: eFORCE 56V
• Motor Type: Brushless
• Batteries Tested: (3x) 8.0 Ah
• Max Air Volume: 795 CFM
• Max Airspeed: 195 MPH
• Max Blowing Force: 25 Newtons
• Warranty: 2 Years Commercial

Greenworks Commercial Optimus

• Model: BB361
• Battery Platform: 82V
• Motor Type: Brushless
• Batteries Tested: (2x) 8.0 Ah
• Max Air Volume: 755 CFM
• Max Airspeed: 225 MPH
• Max Blowing Force: 36 Newtons
• Warranty: 2 Years Commercial

Husqvarna

• Model: 550iBTX
• Battery Platform: 36V
• Motor Type: Brushless
• Battery Tested: BLi950X
• Max Air Volume: 551 CFM
• Max Airspeed: 148 MPH
• Max Blowing Force: 21 Newtons
• Warranty: 2 Years Commercial

Kress Commercial

• Model: KC500.9
• Battery Platform: 60V
• Motor Type: Brushless
• Battery Tested: KAC810 CyberPack 11 Ah
• Max Air Volume: 900 CFM
• Max Airspeed: 190 MPH
• Max Blowing Force: 35 Newtons
• Warranty: 3 Years or 750 Hours of Use Commercial

Milwaukee M18 FUEL

• Model: 3009-24HD
• Battery Platform: 18V
• Motor Type: Brushless
• Battery Tested: (4x) M18 FUEL 12.0 Ah
• Max Air Volume: 650 CFM
• Max Airspeed: 155 MPH
• Max Blowing Force: 20.5 Newtons
• Warranty: 3 Years Commercial

Stihl

• Model: BGA300
• Battery Platform: 36V
• Motor Type: Brushless
• Battery Tested: AR3000L
• Max Air Volume: 571 CFM
• Max Airspeed: 192 MPH
• Max Blowing Force: 26 Newtons
• Warranty: 2 Years Commercial

Backpack Blower Battery Systems

Determining the best battery backpack blower requires testing tools with the largest battery packs available. We requested each manufacturer provide us with the largest battery pack(s) currently available for their platform and the corresponding charger system. As a result, our charging stations look much different than in previous H2H tests! To provide performance and run-time comparable to gas-powered blowers, the battery models we tested rely upon either a large suitcase-style battery or a combination of smaller packs. Here is a breakdown of the batteries and chargers we used.

Echo

The Echo DPB-5800T is powered by any combination of up to three 56V batteries. While the kit version of this tool features two 5.0 Ah eFORCE batteries, we tested the tool with three 8.0 Ah batteries. We have a full review article of the Echo backpack blower available here. Additionally, Echo provided us with an eFORCE Rapid Charger to use during testing. The rapid charger will completely charge an 8.0 Ah battery in about 60 minutes.

Greenworks Commercial

The Greenworks Commercial model accepts two 82V batteries. The tool is capable of operating on a single battery. The tool will draw from both batteries simultaneously when two are inserted. We used two 8.0 Ah batteries, the standard offering in the kit configuration for this tool. The GWC batteries feature Bluetooth connectivity and digital display screens indicating charge levels. The charger tested is the dual port rapid charger. It is capable of charging two 8.0 Ah batteries in about one hour.

Husqvarna

The Husqvarna BLi950X battery is a large suitcase-style battery, as previously mentioned. It is a 36V, 31.1 Ah, behemoth! The 550iBTX backpack blower is only compatible with this style of battery pack. However, the battery is cross-compatible with all Husqvarna handheld 36V tools. The battery includes a standalone backpack frame for carrying when in use with handheld equipment. It also includes an adapter plug which is compatible with all Husqvarna chargers. We used a QC500 charger during testing. A full recharge of the BLi950X is approximately three hours.

Kress

The Kress Commercial Cyber System of batteries offers a variety of solutions. We tested the blower with the larger 60V CyberPack battery which is 11.0 Ahs. However, the Kress blower is also compatible with any 60V CyberPack battery, such as the smaller 4.0 Ah battery pictured above, borrowed from a Kress 16″ chainsaw. The graphene cores of the Kress batteries and the high-output Kress chargers allow a full recharge of the large suitcase-style battery in approximately ten minutes. This is an astoundingly short time compared to the other tools tested.

Milwaukee

The Milwaukee M18 FUEL battery platform is a staple of the tool industry. The kit option of their backpack blower includes a total of four 12.0 Ah M18 FUEL batteries. There are four battery ports on the blower and a minimum of two batteries must be inserted to run the tool. Each pair of batteries is drained simultaneously. It will then automatically switch to the second pair of batteries if all four batteries are inserted. We used the Milwaukee backpack blower with all four batteries inserted during testing. The kit option includes two dual-port Milwaukee Rapid Chargers. These chargers will charge two 12.0 Ah packs in about two hours.

Stihl

The Stihl AR3000L battery is the largest battery we tested. It features 41.20 Ahs on Stihl’s 36V battery platform. This large suitcase-style battery is also compatible with all Stihl handheld equipment with an adapter cable. A backpack-style platform is also available for the battery. We used a Stihl AP Adapter to connect the battery to an AL 500 high-speed battery charger during testing. The total recharge time is about three and a half hours using this combination.  Stihl recently announced their new ADA 1000 battery adapter. It allows two smaller AP series battery packs to power a large output tool like the BGA300 backpack blower—an outstanding accessory for any pro user currently on the Stihl AP battery platform.

Pitot Tube Performance Testing

To flush out generous marketing specifications from true performance for each of our tools, we employed a pitot tube test rig. This test is a specialty of Tool Box Buzz Crew member Jeff Deitz. Jeff, also a helicopter pilot, explained that a pitot tube probe measures the pressure difference of an air stream and can calculate fluid flow velocity. The Pitot Tube was invented by a French engineer, Henri Pitot, in the early 18th century.

Pitot tubes are widely used to determine the airspeed of aircraft, the water speed of boats, and the flow velocity of liquids, air, and gasses in various industries.

When manufacturers test their blowers to come up with the MPH and CFM values they follow an American National Standard (ANSI) procedure to measure the force or thrust. This is effectively an electronic scale that measures the force in Newton’s 5 inches from the blower nozzle. You can read more about the theory behind our pitot tube test rig in our Best Cordless Blower 2023 H2H article.

The Pitot Tube was set up 5 inches from each blower in the center of the air stream. Batteries were fully charged and measurements were taken at max speed setting. The data was collected at a 1 Hz sample rate or once per second for five minutes for the first test. Our second test is another five-minute recording, with the battery depleted to 25% charge.

An ExTech HD350 Pitot Tube Anemometer was used to perform this test.

Max Air Speed Winner – Greenworks Commercial

The Greenworks blower produces airspeeds over 176 MPH. We are unable to determine the exact speed because our testing monitor maxes out at 176 MPH! This is another remarkable performance for the big green machine. In second place is Stihl at 160.7 MPH. An interesting data point is that the Stihl produced slightly higher numbers on the second test run with the battery depleted down to 25%  charge. The BGA300 automatically downshifts its battery system to normalize output and performance regardless of charge charge level.

Measured MPH Results

Third place went to Echo at 150 MPH, fourth place Husqvarna at 137.5 MPH and fifth place went to Kress at 137.3 MPH. Milwaukee was our bottom finisher at 117 MPH.

Max Air Volume Winner – Kress

Using the data collected from our ExTech HD350 meter we were able to calculate the max airflow for each tool in cubic feet per minute (CFM). The Greenworks Commercial blower is the only tool that maxed out our anemometer. Therefore we added a value for Greenworks in our calculations of 200 MPH. This is a close representation of the actual value based on the tool’s performance in all of our testing. Greenworks claims that the max CFM on the tool is 225 MPH.

Calculated CFM Results

Kress is our first-place winner for air volume with a max calculated CFM of 808.44. The Kress has the largest nozzle diameter of all of the tools tested at 3.5″. This allows the Kress to move a massive volume of air. In second place we have Greenworks at 779.70 CFM. Greenworks utilizes a smaller diameter nozzle than Kress but has faster airspeed. This combination of factors still results in an impressive amount of air moved.

In third place is Milwaukee at 548.39 CFM, fourth place is Husqvarna at 545.09 CFM, and fifth place is Stihl at 531.47. Our sixth-place finisher is Echo at 220.48 CFM. This surprised our crew given that Echo performed so well in the airspeed (MPH) test. However, the Echo nozzle chokes down to 1.75″ diameter which is half the size of the Kress. Echo favors speed, but a wider nozzle would likely improve CFM output.

Max Run-time Winner-Stihl

Run-time is one of the most discussed and important categories we evaluated with our backpack blowers. Commercial users require a tool that will accomplish most tasks without constantly switching or recharging batteries. We tracked the total run-time on our blowers by combining our five-minute intervals with the pitot tube along with the time spent depleting the batteries completely. All of this was done at the highest power output setting of each tool. Fall cleanup season is quickly approaching and our entire test crew agreed that we all default to the highest setting on our blowers for tasks like this.

Measured Runtime Results

Our winner here is Stihl with a total run-time of 45:23. The crew expected nothing less from the Stihl, considering the monster 41.20 Ah battery pack that was included with the BGA300. Second place went to Echo with a total run-time of 41:15. The three large 8.0 Ah batteries used with the Echo made this a close race with Stihl.

Third place went to Husqvarna at 39:41, fourth place to Greenworks at 38:36, and fifth place to Milwaukee at 25:45. Kress came in sixth place at 19:51, which is less than half of our top two finishers. However, Kress’ lightning-fast recharge times are somewhat of a redeeming quality compared to the short run-time.

Power Sled Test | Winner-Greenworks Commercial

When life gives you backpack blowers, you build a rocket ship! In our previous handheld blower H2H, the crew used a weighted sled to test the total blowing force of the tools. This time we stepped up the test rig to accommodate our larger and more powerful commercial backpack blowers.

The testing site we used for the day provided us with access to some heavy equipment. A twenty-foot-long Hud-Son firewood conveyor was used as a ramp. We set the conveyor at a seven-degree angle with the help of a PTO hitch on a tractor. Then a classic Radio Flyer wagon was used as our test vehicle. We added a large galvanized washtub to the wagon to act as an air collector. This is a textbook example of Swamp Yankee engineering.

With the test rig in position at the bottom of the ramp, our operator held the end of the blower nozzle in line with the edge of the test rig. The operator then activated the tool on the highest output setting and held it for ten seconds. If the sled moved, we recorded the distance traveled using a tape measure on the conveyor belt. Our unloaded sled weighed in at 34.76 pounds.

All of our tools were able to move the unloaded sled. We then added five pounds to the sled (39.76 Pounds) and continued testing. Two of our blowers were completely unphased by the five-pound increase, while the others showed significant struggle. We then worked up to a fifteen-pound weight (49.76 Pounds) with the two strongest performers and repeated the test.

Power Sled Results

Greenworks is our strongest performing tool, driving the fifteen-pound loaded sled to a distance of 13.25 feet and holding steadily. Kress is our second-place finisher driving the same fifteen-pound loaded sled a total distance of 12.17 feet. Both of these blowers greatly impressed our crew during this test. Both had near-instant spooling-up to power and moving the sled. It felt as though the sled began moving as soon as the control was engaged, regardless of the weight.

Power Sled Results

Milwaukee finished in third place driving the five-pound loaded sled a total of 13 feet. Echo and Stihl were also able to drive the five-pound loaded sled. However, Husqvarna was unable to move this sled and maxed out during the unloaded test.

The overall power of a back blower is dependent upon a combination of features like nozzle diameter, maximum airspeed, and the volume of force the tool puts out. Each of our blowers has its own secret sauce approach to creating power. The Power Sled rig is an excellent visual representation of these different approaches. The stats we listed above, such as MPH and CFM, are shown in actual use with the sled. Overall, the tools with larger nozzle diameters and faster airspeeds performed best, such as our top two tools Greenworks and Kress. Conversely, blowers with fast airspeeds and narrow nozzles, such as Echo, struggled to perform well in this test.

Noise Output Winner-Husqvarna

Reduced noise pollution is often cited as one of the primary benefits of battery-powered OPE. Commercial users of backpack blowers also benefit from reduced engine noise while maintaining occupied residences or office buildings, and noise pollution-restricted areas. However, are commercial battery-powered options quiet enough?

We measured the decibel output of each battery-powered blower and our gas-powered sample. Measurements were taken at the ear of the operator and a 15′ offset. The two measurements show what the noise impact would be for both the operator and a possible pedestrian walking by. Readings were recorded at the highest captured decibel level according to our meter while the blowers were set for maximum output. We ranked the tools based on the at-ear decibel level due to the long-term potential impact on the operator.

Measured Decibel Output Results

Husqvarna is the quietest tool tested at 74.7 decibels. This is well below the OSHA threshold for required hearing protection. Furthermore, the Husqvarna has an impressive tone that is almost pleasant to the ear compared to a traditional backpack blower. In addition, Husqvarna is the quietest tool at our 15-foot offset distance.

Our top five finishers are under the OSHA 85-decibel threshold for hearing protection requirements. In contrast, the Greenworks Commercial blower was the only backpack blower over this 85-decibel threshold at the operator’s ear.

Weight Winner-Milwaukee

Weight is a big consideration for commercial users, who will likely be using the tool for eight hours or more daily. Battery-powered backpack blowers are faced with a tough compromise between a large enough battery for commercial use, while not weighing as much as a Volkswagen. We weighed all of our tool samples as a bare tool only and fully assembled with batteries inserted, however we ranked them by the assembled weight.

Our first-place finisher is Milwaukee with the lightest assembled weight of 32.08 pounds. This impressed the entire crew, especially considering that Milwaukee uses four large 12.0 Ah batteries.  A close second-place finish is Kress at 32.12 pounds. This is also impressive given the large suitcase-style CyberPack battery. Third place is Greenworks and Echo in Fourth. Husqvarna finishes in our fifth-place slot at 34.52 pounds and Stihl finishes the category in sixth-place at a hefty 36.16 pounds.

Measured Weight Results

Each of our tools increased by at least fifteen pounds when adding the weight of the necessary batteries. However, our bottom two finishers, Husqvarna and Stihl, saw weight increases of over twenty pounds after inserting batteries.  An interesting comparison to this is our gas-powered model. The gas-powered tool was the heaviest bare (empty fuel tank) tool tested but gained about two pounds when fully fueled. It is still almost six pounds lighter than our lightest battery-powered unit.

Features and Ergonomics Winner-Greenworks Commercial and Stihl

For this category, we focused on six major areas with our tools:

• Controls
• Grip Ergonomics
• Harness Comfort
• Ease of Battery Change
• Tube Adjustment and Storage
• Fit and Finish

Each tool was assigned a point value from 1 to 3 for each category, with 1 point being the most desired. The total score for all six categories was then calculated and the tools ranked based on the lowest total points to the highest.

Features and Ergonomics Results

In this category, Greenworks Commercial and Stihl tied for first place. Echo claimed our second-place slot, Kress in third, Milwaukee fourth, and Husqvarna in fifth.

Controls

Grip Ergonomics

Harness Comfort

Ease of Battery Change

Kress features the easiest battery change system of all of our tools. The large suitcase-style pack slides out easily with an easy-to-reach release button. Echo, Greenworks, and Milwaukee are all very comparable in terms of battery change. The individual packs are slid out or inserted in order to power the tools. Echo has a slight advantage over the other two, due to all the packs being vertically oriented and easy to access. Greenworks has a spring-loaded cover obstructing the batteries, while Milwaukee positions the batteries in different positions on the external frame.

Stihl and Husqvarna utilize more complicated battery change systems due to the size of the battery packs. Stihl features a rotating cam-lock to secure the battery pack once lined up. It is a little tricky to line everything up at first, but it secures the battery completely with no movement once engaged. Husqvarna requires two sliding plastic tabs to secure the battery from the side, which are difficult to align properly. A power cable must then be run from the battery to an adapter plug on the side of the tool housing. Additionally, the battery must be manually turned on before the tool can be turned on. Our entire crew agreed that this is annoying, especially when considering that it is impossible to reach this switch with the backpack on.

Tube Adjustment and Storage

Milwaukee and Stihl both utilize a telescoping tube design that collapses for storage. In addition, the control stick position is easy to adjust using a cam-pock system. This collapsing feature is ideal for shrinking the overall profile of the tool for storage.

All of our tools, except for the Echo, feature a clip or strap system to secure the tube to the tool body for storage. Milwaukee and Stihl feature heavy-duty metal hooks to secure the tube in a proper upright position.  Kress and Husqvarna both secure the tubes across the harness which causes the tube to hang off to the side and is awkward. The Kress hook also does not stay attached and comes off easily, which was frustrating for our crew. Greenworks secures the tube pointing upwards but uses a thin plastic molded clip that pops off easily and likely won’t hold up to long-term commercial use. Echo needs to include some form of attachment to secure the blower tube.

Fit and Finish

All of our tools tested are designed with commercial users in mind. Therefore we expected excellent fit and finish on all of the models that are still rugged enough to survive getting beat up on a job site or in a tool trailer. Overall we were impressed with the majority of the tools.

Echo, Greenworks, and Husqvarna all used heavy-duty fasteners and steel hose clamps in the construction of their tube designs. Milwaukee and Stihl utilized plastic connectors and clamps, however, they are thick and strong enough that they held up well during our testing without issue.

Kress uses a thinner grade of plastic on their tube and connectors than all of the tools we tested. This results in a lighter felt tube in the hand, but our crew expressed concern over this holding up over long-term, commercial use. During testing the plastic connecter that held the control stick in place repeatedly became loose and would not lock in place. We had to repeatedly tighten it with tools during testing to secure it.

Price Winner-Echo/GreenWorks Commercial/Milwaukee

In this category, we ranked all of our blowers based on the total kit price. Kit prices are most applicable as many professional users will be investing in a battery product for the first time. Due to the substitutions in battery packs used for testing, we built our kit pricing to mirror the setups listed above. We used the ACME Tools website to price as many of the tools as possible.

Price Data Results

We ranked our tools based on price and included this category in the overall rankings. Unlike other H2H tests, our entire test sample is made up of commercial-grade tools designed for demanding pro use. This levels the playing field.

First place in this category is a three-way tie between Echo, Greenworks, and Milwaukee. All three options are available as a kit for $1,500.00. However, Greenworks and Milwaukee both include dual port chargers in their kitted options while we priced the Echo out with a single rapid charger, as tested. The Echo is available as a kit with a dual port charger and two smaller battery packs currently. The price point of all three of these blowers is very reasonable when considering the power and performance of each as well as the additional tools available on the battery platform.

Second place goes to Husqvarna at $1,830.00. Stihl is in third at $2,410.00 and finally we have Kress in fourth at $2,680.00. Kress’ innovative battery and charger system comes with a hefty price tag. The Kress charger is almost $800.00 on its own. Husqvarna and Stihl are two of the most well-known brands in the OPE industry. While they represent a high cost of initial investment, they are both of extremely high quality with huge dealer support and other available tools and equipment.

Our pricing breakdown may come as a shock to some of you. Battery-powered options represent a significant price increase compared to traditional gas-powered options. For example, our pro-grade Echo PB-770T bower that was used as a comparison in some of our testing has an MSRP of $550.00. That’s roughly a third of the cost of our cheapest commercial battery-powered option. The initial investment of the Greenworks Commercial model ($1,500.00) would roughly cover the cost of two Echo PB-9010 gas-powered backpack blowers, the current world’s strongest backpack blower.

Best Commercial Battery Backpack Blower Winner-Greenworks Commercial

Greenworks Commercial emerged as the top performer in several key categories, including max airspeed and power output, making it a powerful choice for high-demand tasks. Stihl impressed with exceptional run-time, ideal for prolonged use, while Kress delivered outstanding air volume performance and record-setting recharge times, perfect for those prioritizing quick battery turnaround.

Milwaukee stood out for its lightweight design, striking a balance between portability and performance. Echo and Husqvarna also had strong showings, though they each faced challenges in categories like weight, ease of battery change, as well as some other comfort and ergonomic-related issues.

Overall Rankings Results

Best Value Winner-Greenworks Commercial

Ordinarily, our best value winner is a tool that offers outstanding performance compared to price. However, in this Head-to-Head our overall winner is also one of our most affordable tools! Greenworks tied for first place in our price category. When comparing the amount of performance the Greenworks is capable of, in addition to its features, our entire crew agreed that the Greenworks is the best all-around value of all of our tools tested.

Final Thoughts

Our comprehensive testing of battery-powered backpack blowers serves as a valuable buyer’s guide for professionals in search of the best tools for their needs.

As professionals evaluate their options, it’s essential to consider not just performance metrics but also the availability of local dealer support. Companies such as Echo, Husqvarna, and Stihl excel in this area thanks to well-established dealer networks and support services as well as box store options.

Choosing a brand with strong local representation can significantly enhance the ownership experience, providing easier access to service and replacement parts. Ultimately, the best choice will depend on specific needs—whether that’s raw power, battery life, or ergonomics.

Speaking of service! Follow the Buy Now links below to purchase some of the blowers featured in this article from our friends at ACME Tools.

Best Battery Backpack Blower | Video Review

Best Commercial Battery Backpack Blower Head-To-Head 2024 is a post from Tool Box Buzz

ECHO hosted their annual POWER-ON-ATHON event on September 19th at their headquarters in Lake Zurich, IL. They invited a number of industry and media partners as they announced new products for 2025. This event included a factory tour, product release, and tool test.

Factory Tour

During the factory tour, Ryan Ladley, VP of Operations at ECHO, spoke about a few major focuses for their manufacturing of high end tools. They were safety, vertical integration, continuous improvement, and listening to feedback from their employees and customers. Let me break that down a little further.

Safety:

As ECHO has updated their manufacturing facility, they have made various changes to the assembly line. One of the biggest focuses for them has been the safety and health of their employees. They spend a significant amount of money to ensure that the team has an ideal quality of life and enjoys their work. Some of the improvements to the work line seem simple, but have prevented overuse or work related injuries for employees.

Vertical Integration:

This was a topic that Ryan brought up numerous times throughout the tour. COVID was a challenge for every vendor/supplier. ECHO felt the impact of material and part delays just like every other company. Their response was to bring more processes in house and improve the efficiency of their operations. In essence, they wanted to control their own destiny. This required keen attention to detail. ECHO brought an automation team, molding team, and maintenance team in house. All of this investment allows them to move towards a more self-sufficient supply chain.

Continuous Improvement:

The focus on improving their manufacturing operation was displayed in their quest for quality. For example, ECHO has invested heavily in automation. This investment allowed for improvements in the overall quality of their offering, reduced their scrap rate, and used new, innovative manufacturing methods. They even go as far as regrinding their scrap so that they can reuse the plastic. Today, ECHO has effectively eliminated all manufacturing waste.

Listening to feedback:

ECHO has implemented a few notable ways to gather high quality feedback. Externally, ECHO has implemented their User Advisory Group (UAG). The UAG members are end users (landscapers, carpenters, etc) that they rely on for feedback on their products and suggestions for future development. Internally, they host annual Kaizen events. During these sessions, they invite employees from various levels in the company to collaborate and determine what they can do to improve.

The tour ended with a walk through their warehouse. It was incredible how much product they keep on demand in order to stay ahead of demand.

Product Release

After the tour, the main attraction…the ECHO POWER-ON-ATHON product announcement. For 2025, a total of 10 new products were launched. This includes:

• 4 blowers (DPB-2610, DPB-5900T, DPB-7700T, DPB-2500LE)
• A rapid field charger
• 2 string trimmers (DSRM-225, SRM-2120)
• A hedge trimmer (DSHC-2600)
• A handheld pruning saw (DHS-3006)
• A gas mower (LM-2119SP)

Tool Test/First Impressions

Next up, we were able to test out the new products. Here are our first impressions!

Blowers:

ECHO continues to deliver on high quality blowers for the homeowner and professional alike. The 2610, 5900T, and 7700T are all part of the X Series. The DPB-2500LE is a limited edition blower in which ECHO partnered with Susan G. Komen. All of these blowers put out an impressive amount of power. ECHO’s 56V batteries produce an impressive run time in all of these continuing on the likes of the 5800T.

Rapid Field Charger:

The 6-port Field Charger was designed for commercial landscapers. This comes with awesome features like their trailer/wall mount. With electric tools becoming more prevalent on job sites, this charger allows you to charge 6 batteries at once, ensuring you’re ready for the next job.

String Trimmers:

ECHO’s Speed-Feed trimmer heads make reloading trimmer line a breeze. The DSRM-225 combines this technology with a light, durable carbon fiber shaft and battery power. This makes it a great option for homeowners looking for a low maintenance trimmer. The SRM-2120 utilizes gas and the Rapid-Loader head. And with an incredible price point of $199.99, this trimmer is an unbeatable value.

Hedge Trimmer:

Another addition to the X Series line is the DSHC-2600, however this time with a battery. ECHO designed this to incorporate a 7-degree angle which allows the operator to use the trimmer with added comfort. The blades are also designed to improve cutting efficiency, and the battery allows for quiet operation of a typically noisy tool.

Handheld Pruning Saw:

The DHS-3006 has a 6” bar and cuts through branches with ease. This new tool is one of the lightest, most powerful pruning saws on the market and is a great addition to anyone’s chainsaw collection.

Gas Mower:

Considering battery powered mowers consume a lot of juice, a gas powered saw was a nice return to conventional mowers. The LM-2119SP easily adapts to walking speed meaning you no longer need to fight the controls to find your Goldilocks setting. And the dual-blade design means you get a professional cut.

Recap

All of these great releases continue to improve on ECHO’s established reputation for quality in outdoor power tools. The ECHO POWER-ON-ATHON event was a great success! We look forward to getting our hands on these tools and seeing the ECHO line continue to grow. Check out the ECHO Press Release from the event for more info!

ECHO POWER-ON-ATHON 2024 is a post from Tool Box Buzz

DEWALT 20V XR 2-1/4 Peak HP Plunge Router DCW620B

20V MAX XR 2-1/4 Peak HP Plunge Router

Manufacturer: DEWALT
Model number: DCW620
Price: $349
Power source: 20V Max Battery
Motor size: 2 1/4 HP
Weight: 11.25 lbs ( Bare Tool)

A Legacy of Excellence

This plunge router is the result of nearly four years of development. DEWALT building on its experience with the successful 1-1/4 HP cordless router and a corded 2-1/2 HP model, aimed to push the boundaries of cordless technology. Drawing on its legacy dating back to Porter-Cable days, DEWALT sought to elevate the router’s performance to the next level with a 2-1/4″ HP cordless router.

This 2-1/4 horsepower heavy-duty plunge router has been designed with DEWALT’s signature attention to detail, the DCW620B offers the rugged durability, advanced features, and user-centric controls that pros need for precision work on demanding job sites. From its intuitive grip design to its innovative Anti-Rotation Safety System, this router is engineered to deliver exceptional performance while keeping you in control.

Why XR and Not FlexVolt?

Some may wonder why DEWALT opted for the XR 20-volt battery platform instead of the FlexVolt 60-volt system. The decision was driven by advancements in electronics and battery technology, which allowed them to achieve top-tier performance with a 20V battery. Additionally, their larger user base is mostly on the 20V platform, it made more sense for them to tailor the router to this group, maximizing accessibility, and of course profit.

DEWALT 20V XR 2-1/4 Peak HP Plunge Router |Features

• Anti-Rotation Safety System
• Variable Speed Dial – 11k -23k RPM
• Tool Free Depth Adjustment System
• 3 Position Adjustable Turret Stops
• Thumb activated plunge lever and lock
• Dual angled LEDs
• Integrated Dust Collection

Collet and Bit Change

The DEWALT 20V XR 2-1/4 Peak HP Plunge Router comes with two sized collets, the ¼” and the ½”. A pronounced and large spindle lock button along with the provided wrench allow for a straightforward bit and collet change with just one wrench.

Grip Mounted Activation

Proper handling of the router required two hands on each of the angled grips. The right grip house the on/Off trigger switch. To power the tool on you need to flip down the lock off lever that is mounted on the trigger and then squeeze the trigger to activate. A “soft start” activation minimizes jerk. With the trigger integrated into the main handle it is intuitive to continue to grip the trigger in the on position to keep the tool activated. Alternatively, there is a lock on switch located by the right thumb if you prefer.

Plunge Base and Depth Adjustment

The plunge lock lever is another highlight, located on the left grip, it is designed for precise depth adjustments. Inspired by DEWALT’s 3-1/4 HP router, the lever’s length and angle were adjusted for easier operation, providing a more ergonomic and comfortable user experience. This new design reduces the risk of unintentional movement during plunge applications, allowing for smoother, more controlled cuts.

The router plunge motion is locked by default. To lower router the plunge lock lever located by the thumb can be depressed while applying downward pressure against the springs. Releasing the thumb lever will lock the plunge depth at that height. The plunge lever can be locked in it down position with an audible click. The plunge motion is then free to go up and down with simple pressure on handles (or lack thereof) without the need to have your thumb on the lever.

The router features a straightforward depth rod with depth guide markings. The router has a maximum routing depth of 3.15″. The rod can be easily locked and unlocked with a quick release lever. The base of the depth rod has micro adjustment feature that can be manipulated by hand without any tools.

Additionally, the rotating turret stop for multi pass through cuts features individually adjustable tiers. These stops do require a wrench to adjust so we envision these will seldom need adjusting but it is a nice option to have.

Anti-Rotation Gyroscope System

The wide dual handed grips give the user great control and stability with cutting. However, this 2 ¼ HP router has a ton of power and is meant for big cuts with large bits. Large bits combined a lot of power has the recipe for serious kickbacks torquing motions. Perhaps the greatest feature of this router is the Anti-Rotation Gyro System, borrowed from other DEWALT tools like drills. This system senses motion and automatically shuts down the tool for added safety.

If a sudden twisting motion is detected, the motor will immediately power off saving the user the need to battle a potential out-of-control router. The tool will not power on again until the power switch is deactivated, and the Anti-Rotation light goes out.

Overload Protection

Located right next to the Anti-Rotation light is a triangular light that indicates an overload state. If the router detects you are pushing the bit too fast into the material a white LED will flash until pressure is reduced and RPMs increase.

Dust Extraction

The DEWALT DCW620 features an integrated dust collection system that starts with a clear plastic shroud designed into the baseplate. The router’s vertical dust chute offers improved line-of-sight while cutting. DEWALT recognized that many users position a vacuum hose over their shoulder for ease, and this vertical design makes that setup much more convenient. Dust is extracted up through the right plunge column where a vacuum hose can be connected. The tool comes with a dust extraction tube adapter that mates with the top of the column and is design to connect to a compatible DeWalt quick lock system.

Unfortunately, if you do not already have a DEWALT quick-lock or AIRLOCK compatible system, dust hose connection can be awkward and frustrating.

Overall, the dust extraction is excellent. When performing cutting on an edge like a round-over or chamfer, an additional dust collection shroud can be attached to collect dust and chip falling below.

Speed Control and Closed-Loop Electronics

While most cordless routers operate at around 25,000 RPM, DEWALT chose to run this model at a slightly lower 23,000 RPM. The router’s closed-loop electrical system was designed to maintain this speed even under load, ensuring a consistent and controlled performance. This deliberate decision gives the router better control over speed and torque, unlike competitors whose performance dips under pressure.

What’s Included

• (1) 20V MAX* XR® 2-1/4 Peak HP Plunge Router (Tool Only)
• (2) Sub-base
• (1) 30mm Guide Bushing
• (1) 1/4 in. (6.4mm) Collet with nut
• (1) 1/2 in. (12.7mm) Collet with nut
• (1) Wrench
• (1) Dust cap
• (2) Dust Shield
• (1) Dust port w/ AIRLOCK Compatibility
• (1) Chip collector
• (1) Centering cone

The DEWALT 20V XR 2-1/4 Peak HP Plunge Router is a plunge base only tool, that is it does not come with a fixed based like some of its competitors. The router comes with two sub bases, one optimized for dust extraction and the second for use with guide bushings for template work.

The router comes with both a 1/4″ and 1/2″ collet and a single wrench for collet and bit changes. Additionally, a centering cone is included if the base plate needs to be adjusted or replaced.

What’s NOT included

With the DCW260B only being sold as a “Tool Only” option there are a few things that you may find yourself searching for.

First and foremost is the recommended power option. While any 20V Max battery will power the router, DEWALT themselves recommend that to get the true performance out of the tool, a 20V Max Power-stack battery is required.
The DEWALT 2 1/4 HP Plunge Router is also compatible with an edge guide or side fence. Unfortunately, no side fence is included and must be purchased separately.

DEWALT 20V XR 2-1/4 Peak HP Plunge Router | Price

DEWALT only offers the DEWALT 20V MAX XR 2-1/4 Peak HP Plunge Router as a bare tool. It is currently priced at ACME Tools for $349. It is our hope that they will soon offer this router kitten with XR batteries and a storage case to protect the tool and accessories.

Final Thoughts on the DEWALT 20V XR 2-1/4 Peak HP Plunge Router

The DEWALT 20V MAX XR 2-1/4 Peak HP Plunge Router isn’t just another plunge router; it’s a robust tool crafted for professional-grade applications. From the moment I turned it on and heard its smooth starting powerful sound I knew this was going to be a next-level router for them.

With features like the Anti-Rotation System, variable speed control, and integrated dust collection, it’s clear that DEWALT has put serious thought into the needs of contractors. The power of this router is also impressive, and you can hear it when routing Oak, Maple and Poplar.

While the router’s price and the “Tool Only” configuration may require some additional purchases, the power, versatility, and safety this tool offers make it a worthy investment for those who demand the best from their tools. Whether you’re making precise cuts on a custom project or tackling heavy-duty tasks like plywood cut outs, the DCW620B is built to perform in the trades.

DEWALT 20V XR 2-1/4 Peak HP Plunge Router Review is a post from Tool Box Buzz

Hydraulic Impact Driver – Should You Have One In Your Kit?

When you hear the term “Hydraulic Impact Driver “you either know exactly what I’m talking about or you wonder if it’s some weird industrial tool hooked up to hydraulic hoses like a giant concrete saw. Well, I can assure you that if you do any work indoors, you should take a closer look at this tool.

What Is a Hydraulic Impact Driver?

So what is a hydraulic impact and how is it different from a regular impact? First off, a regular impact has three main parts a hammer, anvil, and a spring. As the hammer portion turns, if there’s resistance on the anvil, the spring loads up until it releases and the hammer strikes the anvil in the direction of rotation delivering that impact force into the fastener. The hammer and anvil mechanism is all metal so it is pretty loud when activated in quick succession. Check out this video excerpt from ToolStop where a Bosch employee demonstrates the impact mechanism.

A Hydraulic Impact is different in that it uses oil to build up pressure, when the pressure is high enough, pawls get pushed out on the anvil mechanism so that the hammer grabs them as it rotates. Then the pressure decreases, and the pawls retract until the pressure builds again. This results in a much quieter operation.

Benefits of a Hydraulic Impact over a regular

The first and biggest benefit is that they are half as loud as a regular impact. The new Dewalt boasts a 57% decrease in sound over their regular impact when driving 3″ screws into a pressure treated 4×4. That is a significant number. I can guarantee that all of us tradespeople will have some hearing loss over our careers, using a quieter tool when possible only makes sense.

The second benefit is the hydraulic mechanism due to the way it’s constructed, has more sustained torque. A regular impact is like hitting the end of a wrench with a hammer, a hydraulic impact is like putting a cheater pipe over the wrench and giving it a bunch of half-second tugs. Both will tighten the fastener, but one has torque on the fastener for a longer duration.

Killer Applications for Hydraulic Drivers

The obvious applications are anything indoors. MEP Rough-ins, steel stud framing, accessories (mirrors, grab bars, soap, paper towel dispensers, etc), device-ing out, and even doors and hardware. It isn’t just new construction either. Remodeling of existing occupied spaces can always benefit from decreased sound and vibration.

I do a ton of healthcare remodeling, hospitals, clinics, etc. Places that have to stay open even during construction. They always appreciate reduced noise and vibration, especially considering many places have normal sound levels rivaling the local library.

The last killer application is casework (cabinetry). Any time your head is close to the fastener being driven, the quieter the tool, the better it is for you in the long run.

Limitations of Hydraulic Drivers

There are some applications where hydraulic drivers are not the best choice. Longer and larger diameter fasteners like concrete screw anchors (TitanHD) and timber screws are hard for hydraulic impacts (and regular impacts) but in these cases, I usually switch to an impact wrench anyway.

The other area that hydraulics suffer from is extreme cold. I’ve had two Milwaukee Surge hydraulic drivers over the 8 years they’ve been out. The first one only lasted like 3-4 months because I left it on the job in the double digits below zero and I think the oil was too viscous and leaked out when I started using it for the day. I’ve never got an official confirmation from the brands that cold is detrimental for these types of drivers but I’ve read other reports online of similar scenarios.

Who makes Hydraulic Impact Drivers?

Up until a few months ago, Makita and Milwaukee were the only brands that made hydraulics. The drawback to this was that there has been no updates to these tools in the 8 years since they’ve been out. Now Dewalt just released theirs and it boasts quieter operation, less vibration, and more power than the Makita and Milwaukee. I don’t know if this new release from Dewalt will trigger updates to the Makita and Milwaukee.

What I do know is that if you’re on Milwaukee M18 or M12, Makita 18V LXT, or Dewalt 20V a hydraulic impact driver should have a spot in your tool kit.

Where To Buy (ACME Tool)

Milwaukee M12 Surge Bare Tool

MilwaukeeM18 Surge Bare Tool

Makita 18V LXT Bare Tool

Dewalt 20V Quiet Hydraulic Impact Bare Tool

Hydraulic Impact Driver – Should you have one? is a post from Tool Box Buzz

JET AFS-850 Mobile Air Filter Review

JET AFS-850 Mobile Air Filter

4.5/5

Manufacturer: Woodworking Tools
Model number: AFS-850
Price: 699.00
Power source: 120 Volt
Motor size: Brushless: DC, 1/5 HP, 115V
Weight: 31.9 lbs

Why Choose the JET AFS-850?

In the realm of remodeling and construction, the term “livable remodeling” has gained prominence. This approach focuses on delivering building and remodeling services that:

• Reduce Stress: Streamlined processes make the remodeling experience less overwhelming for clients.
• Minimize Health Risks: Effective dust control mitigates airborne dust hazards.
• Ensure Livability: Homes remain comfortable and functional throughout the remodeling process
• Promote Communication and Professionalism: Clear interactions build trust and satisfaction.

Using outdated methods, like a box fan in the window, not only fails to meet modern standards but also violates EPA regulations, which now require certified HEPA equipment to capture and contain dust effectively. A combination of collecting dust at its source, air filtration and dust barriers are the better practices. The JET AFS-850 aligns with these best practices, helping to keep dust from spreading to non-work areas and safeguarding the health of both workers and homeowners.

Summary of Dust Control | Best Practices

1. Set Expectations:
2. Communicate clearly with homeowners about dust control measures.
3. Isolate the Work Area:
4. Use barriers like ZipWall and ZipDoor to seal off the space.
5. Establish Negative Air Pressure:
6. Use air scrubbers to direct dust out of the area or air filters like the JET Filter.
7. Seal Ductwork: Prevent dust from spreading through HVAC systems.
8. Daily Cleanup: Regularly remove dust to maintain a clean environment.

These steps help keep dust contained, protecting other areas of the home and reducing cleanup efforts.

Health Implications of Dust

Dust isn’t merely a nuisance—it poses significant health risks, including:

• Asthma Triggers: Can exacerbate asthma in both children and adults.
• Allergic Reactions: Increases the likelihood of allergic responses.
• Chronic Respiratory Issues: Aggravates conditions like chronic obstructive pulmonary disease (COPD).
• Effective dust control systems like the JET AFS-850 are crucial in mitigating these health hazards, making it a valuable addition to any job site.

JET AFS-850 Mobile Air Filter | Specifications and Features

• Airflow 850 CFM
• MERV 15 Filter: Efficiently removes dust particles ranging from 0.3 to 10 microns, capturing 98% of particles at 1 micron.
• HEPA Certification: Meets EPA requirements for dust containment.
• Whisper-Quiet: Operates at just 50-68dB, ensuring a peaceful workspace.
• Brushless DC Motor: Offers durability, quieter operation, and higher energy efficiency.
• Auto Mode: Utilizes an integrated PM2.5 sensor to monitor air quality in real-time and adjust motor speed,accordingly, optimizing energy usage and extending filter life.
• Bright LED Display: Clear digital readout for easy monitoring of filter status, fan speed, and timer settings.
• User-Friendly Interface: Simple controls for adjusting settings and viewing operational status.
• Lightweight and Portable: Easy to move around the jobsite with a full-ring handle.
• 15-Foot Power Cable: Provides flexible placement near dust generation areas.
• Filter Status Indicators: Visual alerts for filter condition— “GOOD,” “REPLACE SOON,” or “REPLACE.”
• Blower Speeds: 6 Speeds (190-850 CF
• Timer Settings: 1-16 Hours
• Sound Rating: 50-68 dB @ 3.28 Feet
• Filter Type: MERV 15, Pre-filter (washable), Canister Filter, Optional Charcoal Filter
• Motor Brushless: DC, 1/5 HP, 115V
• Power Cable: 15 Feet
• Weight: 31.9 lbs. (14.5 kg)
• Dimensions: 19.134″ x 19.134″ x 36.575″ (LxWxH)
• Filter Options Charcoal (optional)

Operating the JET AFS-850 Mobile Air Filter

1. Switch the Power ON/OFF to the ON position.
2. Press the on/Off button to start the unit. [not sure why it has a double start button]
3. Choose between manual fan speeds or enable Auto Mode for intelligent air quality management.
4. Use the LED display to keep track of filter status and adjust settings as needed.
5. Set the timer to automatically shut off the unit after a specified period (1-16 hours) This can be useful to continue to filter the air after you leave an area.
6. The intuitive control panel makes it easy to customize settings based on the jobsite’s needs, ensuring optimal dust control with minimal effort.

Our User Experience and Operation

We are firm believers in connecting dust making tools to vacuums. That said to see if the the JET AFS-850 Mobile Air Filter worked well we needed to make some dust.

We set the JET filter up in different situations to test it:

• In a room cutting and routing drywall
• Next to a table saw cutting everything from pine, plywood and MDF.
• In a demo area
• Next to sanding and cutting MDF

In the end the best way to show the filter in action was to place it near us when cutting and sanding MDF cabinet panels. We set the JET Filter to AUTO mode and left it alone. Shortly after cutting or sanding the MDF we could hear the filter motor ramp up and stay high for a period until the proverbial saying “when the dust settled,” or in this case was filtered!

Again, I’m not advocating that you sand or cut MDF without dust collection, my point is that this JET filter is part of the overall solution to cleaner air.

Maintenance and Filter Replacement

Proper maintenance is crucial for the longevity and efficiency of the AFS-850 and we noted that after 3 weeks of using the filter we were able to easily clean it with a vacuum.Removing, cleaning or changing out the pre-filter and pleated filter is easy.

Removing or Changing Filter

1. Power Off and unplug the unit.
2. Unlock Fan Head: Place a foot on the base, grasp the ring handle, and turn the fan head counterclockwise.
3. Remove Filters: Lift the fan head and remove the pre-filter and canister filter.
4. Clean or Replace: Wash or vacuum the pre-filter or replace it.
5. Vacuum the canister filter with a brush attachment or replace it if necessary.
6. Reassemble

Its also recommended that you wipe down the integrated PM2.5 sensor clean with a dry cloth or compressed air to maintain accurate auto mode functionality. This sensor is located on the underside of the blower hool.

JET AFS-850 | Pros and Cons

Pros

1. High Filtration Efficiency: MERV 15 filter captures a wide range of dust particles.
2. Quiet Operation: Minimal noise disruption on the jobsite.
3. Smart Controls: Auto mode and intuitive LED display enhance usability.
4. Portable Design: Lightweight and easy to move with a long power cable.
5. Compliance: Meets EPA regulations for dust control.

Cons

1. Price: At $699, it may be a significant investment for smaller operations.
2. Maintenance: Requires regular cleaning and filter changes to maintain performance.
3. Weight: Weighing nearly 32 lbs., it may be cumbersome for some users to move frequently.

Price

The JET AFS-850 Mobile Air Filter can be purchased at ACME Tools

• Jet JT1-229 AFS-850 120V 1 PH 850 CFM Air Filtration System $699.00
• Jet JT1-336 AFS850-016 Inner Filter for AFS-850 – Paper Filter $69.99
• Jet JT1-337 AFS850-CF Activated Charcoal Filter for AFS-850
• $45.99
• Jet JT1-335 AFS850-008 Washable/Re-Useable Pre-Filter for AFS-850 $ 15.99

Conclusion

We liked using the JET AFS-850 Mobile Air Filter and found it to be a robust and efficient solution for job site dust control, aligning perfectly with the principles of livable remodeling.

Its high filtration capacity, quiet operation, and smart controls make it a valuable tool for contractors who prioritize health, safety, and professionalism. While the initial investment is considerable, the benefits of improved air quality, reduced health risks, and enhanced client satisfaction make the AFS-850 a worthwhile addition to any construction or remodeling toolkit.

By effectively managing dust, the AFS-850 not only ensures a cleaner and healthier work environment but also enhances your reputation as a detail-oriented and professional contractor. This can lead to increased homeowner satisfaction and more referrals, ultimately boosting the quality and quantity of your business.

JET AFS-850 Mobile Air Filter Video Review

JET AFS-850 Mobile Air Filter is a post from Tool Box Buzz

Milwaukee M18 FUEL 7-1/4” Circular Saw 2834-20

Milwaukee M18 FUEL 7-1/4” Circular Saw 2834-20

4.5/5

Manufacturer: Milwaukee Tools
Model number: 834-20
Price: 249.00 bare tool | 446.00 kitted
Power source: M18 battery
Weight: 7.9 lbs

Milwaukee M18 FUEL 7-1/4” Circular Saw 2834-20 | Specifications

1. 750 Cuts Per Charge (M18 REDLITHIUM FORGE HD12.0 battery)
2. 2-5/8″ Cut Capacity: Capability to cut 3x material in one pass
3. Bevel detents at 22.5 and 45 degrees
4. Depth detents at 1/2″, 3/4″, and 1-1/2”
5. Integrated dust port on guard and included vac adaptor
6. LED light
7. Integrated rafter hook
8. Magnesium shoe and guards
9. Electric brake
10. Length: 14 in
11. Weight: 7.9 lb.
12. Height: 8.5 in
13. Width: 7.4 in
14. Brushless motor

First Impression

When we first got the new Milwaukee Circular Saw, we put it side by side with the earlier Gen 2 model. The first thing we noticed was that the new saw was much smaller and lighter. Once we made a cut with the saw, my first comment was, “WOW, this cuts smooth!” More on that later.

Accuracy

Not that a lot of people check their saws, but when we checked in the shop, our saw was a perfect 90 and 45 degrees.

Milwaukee M18 FUEL 7-1/4” Circular Saw 2834-20 Updates

Compact Size

Milwaukee tossed out the Gen 2 design and redid this new saw inside and out. They shaved weight and size off the gear case, shoe plate, and upper and lower guards to get a more compact, lighter saw.

Support Handle

The support handle has been moved down in front of the motor. This was done to separate the hands further and create a better opportunity for user control of the saw.

Actuation Safety Trigger

The previous circular saw model had an ambidextrous button that needed to be depressed to activate the trigger and power on the saw. This safety annoyed many users, me included.

Having to actuate this button sometimes made it difficult to use the saw in some positions, like overhead cutting or cutting rafter tails. Milwaukee removed the old button, eliminating the need for a thumb depress.

They changed it to a lock on/off button. Now, when the button is turned on, the saw can be operated from the tool’s trigger without any other safety functions or activations needed.

Finger Guard

You’ll notice a large finger guard surrounding the trigger. This was done to help prevent items from hitting or wedging against the trigger and causing an accidental power-on situation. We found this guard large enough to fit a winter-gloved hand inside.

Blade Adjustment Depth Detents

One nice feature added was the addition of depth detents at 1/2″, 3/4″, and 1-1/2”. This is a little feature that users will appreciate, and once it becomes second nature, they will just feel or listen for the detents and go!

Bevel Lever

The old plastic knob has been replaced with a robust “old-school style” metal lever. The issue we’ve noticed on the older knob was that it often would get loose, fall off, and you’d lose the nut to hold it on. The new lever is securely attached and requires a ¼ rotation to loosen and a simple push down to lock. The saw has two detents at 22.5 and 45 degrees.

Blade Guard Geometry

The new saw has a flared guard end that was designed to eliminate hang-up and improve compound bevel, miter cuts, and thin cuts. We made several test cuts trying to catch up with the guard, and while you can occasionally get it to catch, its design is way better than the Gen 2 model.

LED Light

Milwaukee moved the LED light, and it now points to the cut line and saw blade. We noted that this new LED location really improved the cut line lighting.

Dust Port

I don’t know any tradesmen who use circular saws with dust collection, but it sure is nice to have the option. Milwaukee changed the outer port to have a universal adaptor and eliminate an extra part that the Gen 2 had—one less thing to lose.

Dust Blower

The dust blower uses the motor fan to channel air to three slots in the front of the saw and direct the air to the blade. The slots can be seen near the new LED light location.

Blade Wrench

Milwaukee ditched the old Allen wrench and went back to an old-school-style wrench, placing it in a more secure location, into the saw body just under the battery location. This location seems more secure than the older location and is way less likely to back out.

The wrench itself is bigger and gives the user more to hold onto. You’ll notice a prying section at the wrench’s end, which is a carryover from the old diamond cutouts on blades—even though Milwaukee is eliminating them for a 5/8” round arbor on all their saws.

Guard Spring

While not necessarily new, if you turn the saw upside down, you’ll see the guard safety spring is more visible than the Gen 2. Milwaukee uses what’s called a “Double Bugle Spring,” compared to many competitors that use a J-Spring.

The “Bugle Spring” cones-open on both ends and makes it far less likely for it to come loose under stress and usage. Milwaukee is committed to making safe products. They use the double bugle spring because it’s very reliable option and they test it to the extreme. The goal is to have a guard that always opens and closes properly!

Increased Bevel

The new Milwaukee saw now has the capacity to bevel to 57 degrees versus the Gen 2, which beveled to 53 degrees. The cut capacity does lessen at this angle, but the ability to make that angle cut can be helpful to many carpenters.

New Motor

We like to describe this new motor as power-dense in a smaller size. Milwaukee didn’t shave weight off the motor, instead opting to increase the copper windings, making it 1/10 lb. heavier than the older motor.
Here’s an interesting explanation of motor power:

• Gen 2 Saw #2732: Motor produces approximately 2,000 watts of power with a 12 Ah High Output battery.
• Gen 3 Saw #2834: Motor produces 2500-2600 watts of power with a 12 Ah High Output battery.
• Gen 3 Saw #2834: Motor produces 3200 watts of power with a 12 Ah FORGE battery.

Vent Slots Under Saw

If you look under the saw, you’ll see some vent slots. Vent slots are not new to Milwaukee saws, but these vents pull in cool air to cool off the saw’s components and electronics.

Using this Saw – My Thoughts

Using this saw, I immediately noticed how smooth and effortless it was to make cuts. The bevel adjustment is a standout feature, and I truly appreciate the expanded 57-degree range, which offers more versatility for various cutting angles. The smaller, lighter design makes the saw more maneuverable, and the elimination of the thumb safety actuation switch is a welcome change, allowing for easier operation. The new LED location is another highlight, significantly improving the illumination of the cut line compared to the older Gen 2 model. Additionally, the dust blower does an excellent job of clearing the cut line, ensuring better visibility during use.

The Whole is Greater than the Sum of its Parts

The larger story here is that the new motor efficiency, updated electronics, and new batteries come together to give you a more powerful saw in a smaller footprint.

The following four core components all work together to enhance the Milwaukee M18 FUEL 7-1/4” Circular Saw 2834-20’s performance

1. M18 Forge Batteries

Milwaukee now has more powerful tab-less cell batteries and all-new battery pack construction that can charge faster. They come in the following sizes: XC6.0, XC 8.0, XC 12.0.

2. M18 SUPER Battery Chargers

Active cooling technology COOLCYCLE forces air through compatible battery packs. This airflow can cool overheated batteries within 90 seconds to begin charging.

3. Motor

This is the most power-dense motor Milwaukee has ever created. It has an increase of 36% more copper in the stator windings while reducing the overall size by 15%.

4. Electronics

More robust circuit boards and thicker wires are necessary to handle the increased current flowing between the new batteries and more powerful motors.

The new M18 REDLITHIUM FORGE batteries offer enhanced power in a smaller, lighter design, while the M18 Dual Bay SUPERCHARGER cuts charging time dramatically with innovative cooling technology. The POWERSTATE Brushless Motors have been refined for greater efficiency and power, and the upgraded REDLINK PLUS electronics ensure seamless communication between these advanced components. These enhancements culminate in the new 7-1/4″ Circular Saw, delivering more power, higher RPM, and improved ergonomics in a lighter package, setting a new standard for the M18 lineup.

Price and Availability

ACME Tools offers the Milwaukee M18 FUEL 7-1/4” Circular Saw in two configurations:

1. Bare Tool: $249
2. Kitted: $449, which includes a charger, bag, and a 12Ah FORGE battery. Model # 2834-21HD.

Overall Impression | Milwaukee M18 FUEL 7-1/4” Circular Saw 2834-20

We were blown away by the recent updates to this saw and immediately noticed the difference in power on the first cut. One of my crew described it as cutting “like a hot knife through butter.” Personally, I’d describe it differently. I’ve owned many pickup trucks, and I recently bought myself a used Audi Q5 as my personal car. This saw cuts with the power of my truck’s towing capacity but feels as smooth as cruising in my Audi.

Well done, Milwaukee.

Milwaukee M18 FUEL 7-1/4” Circular Saw 2834-20 Video Review

Milwaukee M18 FUEL 7-1/4” Circular Saw 2834-20 Review is a post from Tool Box Buzz

HILTI Dust Extractor VC 4X-22

HILTI 22-Volt Nuron Dust Extractor VC 4X-22

5/5

Manufacturer: HILTI
Model number: VC 4X-22
Power source: 22 volt battery

Dust Extractor VC 4X-22 | Multiple Configurations

The dust extractor offers several configurations:

• Vacuum head unit
• 8-liter tank that connects to a backpack set
• 15-liter tank that connects to a wheeled dolly
• Plastic bags for silica dust with a zip tie
• Fleece bags specific to sawdust and other debris
• 6-foot hose designed for the backpack and wall drilling
• 9-foot hose for both configurations
• Bluetooth dongle
• HEPA filter
• Universal wet/dry filter

Interesting Note: The plastic bags have holes that should be inside the tank to prevent suction into the filter, allowing better performance with some dust leakage.

Hilti VC 4X-22 |Runtime and Bluetooth Dongle

The Hilti Dust Extractor VC 4X-22 when equipped with a 255 battery, the vacuum runs for 21 to 22 minutes continuously. However, the vacuum is primarily designed as a dust extractor, connected to a tool that powers on and off with the tool. In this mode, the battery can last an entire day or more.

Hilti provides a Bluetooth dongle that can attach on the hose end or directly on the tool.

We recently used the vacuum and dongle on our miter saw while cutting PVC trim. The vacuum ran all day, in an on / off fashion, and battery was half full at the end of the day. To make sure we used the vacuum, we attached the dongle “font and center,” on the miter saw handle. This reminded us to turn it on and off as we made our cuts. The dongle was designed to preserve battery life, and it worked for us.
Interesting Note on Hilti Battery Charging:

The HILTI charger can charge the battery in less than an hour, reaching 80% in the first half hour. So, if you need a battery sooner, you can pull it off the charger after half an hour and be at 80%. Regardless, having two batteries will guarantee you all-day runtime.
Powerhead Design

The powerhead has a top, folding handle that makes carrying this vacuum easy. There are two large, solidly designed clamps to attach the power head to the vacuum tank. The filter attaches underneath the powerhead and is easily removed. The black flange between the filter and powerhead is designed to install only one way on the power head. HILTI updated this because many users were installing it backward, introducing air into the turbine and blowing out the sides.

User Interface Dashboard

The dashboard on the Hilti Dust Extractor VC 4X-22 is intuitive, and has symbol-like labels to assist users, although I still feel that HILTI could improve their manuals. The dashboard has an on/off, and Bluetooth knob.

There is also an LED indicator to alert users when the tank is full of water. Yes, this vacuum can be used as a wet/dry vac, why I’m not 100% sure, I’d rather use a cheap shop vac for that. Maybe Hilti has a connection for concrete wet cutting. There is also an ECO button on the dashboard which allows users to reduce vacuum power to 60% to conserve battery or when 100% suction is not needed, such as in some sanding applications.

Under the head unit, two stainless steel sensors detect water levels in the tank.

Suction and Power

The HILTI VC 4X-22 certainly has plenty of suction for both tool attachment and cleanup. While not designed for heavy debris and demolition waste, it works well for small cleanups. HILTI sells accessories like floor sweeps and nozzles, making this vacuum suitable for both dust extraction and small service call cleanups.

As I mentioned earlier, I used this vacuum on an exterior repair project ripping PVC trim, on a tablesaw, which creates a lot of dust. The vacuum performed excellently, collecting dust from our miter saw. I’ve also used it to collect sawdust and on a few small clean ups.

Filter and Filter Cleaning

HILTI offers fleece bags designed to protect the filter from sawdust, which is especially bad on the filters, sawdust clings to the filter and resists filter auto cleaning. The dashboard has a push button to power clean the filter. It’s recommended that you cover the hose with your hand to build up pressure and press the power clean button 5-6 times. Doing this effectively cleans the filter better than the regular interval auto clean function.

Note: Tapping the filter or using compressed air can damage it. HILTI offers two filters: a HEPA filter and a universal wet/dry filter, each costing around $50 and will last users a few months.

15-Liter Tank | 2-Wheel Cart

The Hilti Dust Extractor VC 4X-22 tank is engineered with reinforced ribbing to reduce collapsing from the increased vacuum power pressure. The larger tank improves performance by maintaining vacuum pressure inside the tank as it fills with debris. The telescoping cart handle works great at maneuvering the vacuum, users can lock the handle height, by activating a rotating pivot lock. Black supports or stair slides mounted on the cart, near the wheels protect stairs during navigation. The cartwheels are durable, navigating gravel, asphalt, and grass adequately, no issues. The front of the cart is extended and provide excellent stability to the vacuum. I place the vac ion the side wall of my van and it stays put and doesn’t tip over.

The tank cart is backwards compatible with HILTI’s VC 140, allowing for an upgrade or exchange through the fleet program

Backpack Harness | 8-Liter Tank Setup

The backpack setup is designed to be used with the smaller, 8-liter tank configuration. It’s designed for users who are wall and overhead drilling. The backpack harness has 4-tabs that intersect into the powerhead and a red clip that locks it in pace. We found the backpack attachment easy to attach to the powerhead and smaller tank. Its comfortable and easy to use.

The backpack harness has plenty of padding  for wall and ceiling drilling.

Anti-static Vacuum Hose and Grounding

To address user feedback about static shocks, HILTI installed internal copper wire inside the vacuum to improve grounding. They also designed an anti-static hose with a conical shape on one end that reduces static.

Conical Adapter

The vacuum includes a conical adapter with ribs on the inside specifically designed for HILTI’s jigsaw and an outside fit for circular saws and other tools like concrete breakers and drills. It also fits our 12-inch DeWalt miter saw, and 7-1/4-inch Milwaukee miter saw.
To connect to my Milwaukee cordless tablesaw I needed to use a different connection adapter, that I had in my bag of tricks.

Room for Improvement

There’s not much to complain about the Hilti Dust Extractor VC 4X-22 other than the cost of the unit. One thing I do notice is that I get annoyed coiling the hose around the telescoping handle. It’s just not as neat and clean as I’d like to see – there was no plan for it. One way I’ve dealt with this is I use a Velcro strap to secure the hose to the vacuum.

Hilti Dust Extractor VC 4X-22 Price

• Vacuum with 8 liter tank:  $549.00
• Vacuum with 15 liter tank $649.00

Conclusion

In summary, we like the Hilti Dust Extractor VC 4X-22. HILTI’s upgraded dust extractor offers improved versatility, power, and user-friendly features, making it a valuable tool for various applications, including wet vacuuming if we were ever in a pinch.

Hilti Dust Extractor VC 4X-22 Video Review

HILTI 22-Volt Nuron Dust Extractor VC 4X-22 Review is a post from Tool Box Buzz

New Milwaukee M18 Tool Improvements

Milwaukee Tools just held their annual PIPELINE media event where they unveiled the latest additions to their expansive product lineup.  The backbone of this years event was touted as THE NEXT BREAKTHROUGH in M18 FUEL ^TM. This next breakthrough is actually as series of iterative improvements across 4 key components that make up the M18 tool platform – batteries, chargers, motors, and electronics.

M18 REDLITHIUM^TM FORGE^TM BATTERIES

At last years PIPELINE event in 2023, Milwaukee announced their newest innovations to the M18 and MX batteries with the REDLITHIUM FORGE series. The M18 XC 6.0 FORGE battery was released taking advantage of a pouch style design that boasted similar performance to the M18 HD 12.0 battery in a package 30% smaller and 40% lighter.

This year the M18 REDLITHIUM FORGE XC 8.0 AND HD 12.0 batteries were announced. These batteries take advantage of a tabless cell structure currently found on the MX series FORGE batteries. This tabless cell structure benefits from a new laser welding process to connect the individual cells allowing for a more robust connection as well as unlocking a feature previously found only on the MX batteries that Milwaukee is calling COOL CYCLE. Open vents in the battery housing allow for active convection cooling when paired with the new SUPER CHARGER.

In addition to the faster charge times and increased power in a smaller package, Milwaukee claims these new batteries extend lifetime performance as well.

M18 Dual Bay Simultaneous SUPERCHARGER

With the release of the FORGE series batteries last year, Milwaukee introduced the new SUPERCHARGER series of batteries chargers. These chargers can recharge the FORGE batteries and previous generation REDLITHIUM batteries significantly faster, roughly 2X faster than the RAPIDCHARGER and 4-5X faster than the standard charger.

This year the SUPERCHARGER is incorporating the active cooling technology COOLCYCLE that forces air through compatible battery packs. This airflow can cool overheated batteries within 90 seconds to begin charging. Without COOLCYCLE ambient cooling could take as long as 20 minutes before charging can even begin. Additionally the airflow will keep the battery significantly cooler, aiding in the quick charge times and helping ease the strain on components over their lifetime.

As seen in the graphic above, the new 12.0 FORGE battery can charge cooled off a high demand discharge and charged in as skittle as 45 minutes with the SUPERCHARGER compared to 127 minutes for the previous gen 12.0 battery and RAPIDCHARGER.

POWERSTATE Brushless Motors

The POWERSTATE Brushless Motors also benefit from a next generation upgrade.  A new manufacturing process that Milwaukee is employing has allowed for an increase of 36% more copper in the stator windings while reducing the overall size by 15%.This is achieved by individual stator segments remain exposed exposed for high efficiency windings and then welded together to form the concentric ring.

REDLINK PLUS Electronics enhancements

To quarterback all these improved components, the electrical curcuits and wiring also recieved an upgrade.  The next generation REDLINK PLUS electronics are built around improved curcuit boards that are smaller yet more robust.  Additionally these boards can interface with much thicker wiring that is necessary to handle to increase current flowing between the new batteries and more powerful motors.

How do all these upgrades add up?

Most tool innovations these days are incremental and the margins by what makes a new version tool “better” can sometimes be hard to quantify or justify a sale.  Milwaukee has spent years making incremental improvements to 4 key backbone components with batteries, charges, motors and electronics.  In the past 12 months we have seen significant upgrades on all 4 of these components starting with the release of the FORGE batteries last year.  But what happens when all 4 get incorporated into a new tool designed from the ground up.

We were excited to see the first tool to incorporate all these upgrades are the new 7 1/4″ Circular Saws, both top handle/sidewinder and rear handle/wormdrive. The new 2834 model is set to replace the existing 2732 model in August 2024.  This newer has been redesigned from the ground up and features some new ergonomic improvements like a redesign of the sometimes cumbersome thumb activated trigger lock.

The new M18 FUEL  7 1/4″ Circular Saw has an increased cut capacity at 2 5/8″, a 1/8″ bump up from the previous generation saw.  The new POWERSTATE motors drive the blade at 6000 RPM, 200 RPM higher than before and produce a peak power output ~50% more.

Additionaly the newer saw is able to deliver all this new performance in a smaller lighter package.  The 2834 weighs in at 7.9 lbs, which is 10% lighter than the previous 2732 weighing in at 8.7 lbs.

While its easy to see how these new core components are delivering a significant bump in performance to the circular saw lineup, the potential to have similar performance gains in smaller packages across the M18 lineup is an exciting development.  While not all tools on the M18 lineup may see as large a performance gain as the saws we are eager to see how these new developments filter through the product lineup.

Milwaukee M18 Fuel Improvements is a post from Tool Box Buzz

Echo DPB-5800T Battery Backpack Blower Review

eFORCE Battery Backpack Blower

4.5/5

Manufacturer: Echo
Model number: DPB-5800T
Price: $349.99 Bare Tool
Power source: 56V Battery System
Weight: 15.0 Lbs. Bare Tool

The DPB-5800T first debuted at the Echo Power Up and Power On media Summit at their US headquarters in Lake Zurich, Illinois. Members of our crew attended this event and participated in product demos.

Echo provided the Tool Box Buzz crew with a sample of the tool for testing. Additionally, our crew had the opportunity to visit Echo’s manufacturing facility in Lake Zurich, Illinois to see where the DPB-5800T is built. All Echo backpack leafblowers sold worldwide are manufactured in this facility!

Specifications

• Voltage: 56V
• Motor Type: Brushless
• Max Airflow Output: 795 CFM
• Max Airspeed: 195 MPH
• Newton Force: 17N (High Mode) / 25N (Turbo Mode)
• Weight: 15.0 Lbs. (Bare Tool)
• Tool Warranty: 5 Year Consumer / 2 Year Commercial
• Battery Warranty: 2 Year Consumer / 1 Year Commercial

Echo eFORCE Battery Versatility

The eFORCE battery platform is Echo’s 56V powerhouse for cordless outdoor power equipment. We have covered several tools on this platform before in our reviews of the Echo DCS-5000 Chainsaw as well as our recent Best Top Handle Chainsaw Head-to-Head. Their batteries are available in 2.5 Ah, 5.0 Ah, and now 8.0 Ah sizes. The 8.0 Ah battery packs debuted along with the DPB-5800T. These larger packs are ideally suited for high-demand tools like a backpack blower.

The Echo battery backpack blower features three battery ports on the outside of the housing. Any combination of eFORCE batteries will power the tool. Whether it’s a single 2.5 Ah or three big 8.0 Ah batteries!

Controls

Controls on the DPB-5800T are intuitive and very user-friendly. Echo only offers this tool in a tube-mounted throttle configuration chiefly because all the controls are within the thumb’s reach on the control stick. An LED display provides the user with battery information. The number of battery packs inserted as well as the remaining battery life is prominently visible. My favorite feature of this display is that the fuel gauge shows the total available power remaining from all battery packs inserted. The tool draws from all batteries simultaneously and adjusts itself according to the size of the batteries.

The variable speed trigger is large and has an excellent curved shape that is very ergonomic. It is comfortable and easy to use even with thick gloves on.  A throttle lock-out lever keeps the tool at your desired speed. This feature is common on backpack blowers. For high-demand applications, the Turbo mode button is front and center. Pressing this button shifts the tool into its highest possible output mode. Although it must be pressed again each time the tool is shut off. The DPB-5800T will not default to Turbo mode.

Echo Power and Performance

Leaf cleanup still isn’t fun, but the lack of noise is greatly appreciated by my wife and our neighbors!

Echo’s published data on the 56V backpack blower shows a top potential airspeed of 195 MPH and output up to 795 CFM. These specs are comparable to most homeowner backpack blowers and some smaller commercial models. Overall during testing, I found the DPB-5800T to have plenty of power for small to medium cleanup jobs. While in Turbo mode the Echo will easily blast through heavy and wet leaves as well as move large piles. During our last New England Fall cleanup, the 56V Echo was an excellent complement to a larger gas-powered blower. It was wonderful to use a tool so lightweight, quiet, and fume-free compared to my PB-9010T.

Battery Runtime

Due to the large variation in battery pack configurations for the DPB-5800T, it is hard to quantify the run-time for the tool. Echo posted the following specs on their website:

• 3x 8 Ah Batteries: 45 Min. Run-time on Turbo / 80 Min Wide Open Throttle (WOT)
• 2x 8 Ah Batteries: 30 Min Run-time on Turbo / 55 Min WOT
• 3x 5 Ah Batteries: 26 Min Run-time on Turbo / 50 Min WOT
• 2x 5 Ah Batteries: 20 Min Run-time on Turbo / 35 WOT

Overall these numbers matched my experience during use. Where the Echo excels in run-time in my opinion, is in support of other 56V tools for small sporadic cleanups. For example, I work with an arborist who uses multiple Echo 56V products daily. At the completion of the job, or after the chipping is done, we clean the roadway and property. Having the freedom to grab any combination of charged batteries and plug them into the ports of the Echo blower is a huge benefit. Landscapers on the Echo 56V battery platform will benefit similarly. The power of the DPB-5800T is well-suited for cleanups like these.

Currently, Echo offers this tool as a kit option with two 5.0 Ah batteries. This configuration provides 35 minutes of continuous run-time, however sporadic use will be far longer. Two 5.0 Ah batteries allowed for multiple days of sporadic cleanup use during my testing. Echo will be offering the DPB-5800T in different kit configurations in the future. This will include the new larger 8.0 Ah batteries.

Overall Impressions

The first time I saw the DPB-5800T I was blown away by the slim and svelte profile of it. Picking it up and experiencing the lightweight design of it was another  “Wo!” moment. The power and performance this tool provides is outstanding. Combined with the ease of maintenance and elimination of excessive noise and fumes, this tool is a great addition to Echo’s 56V lineup. The shoulder harness is comfortable and the controls are easy to reach. Furthermore, the throttle control position and tube length can be adjusted to an individual user’s preference.

I do not think this is a complete replacement for gas-powered backpack blowers. While the DPB-5800T has impressive performance, it cannot keep up with its large high-output gas-powered cousins for large cleanups and all-day use. It would be a logistical nightmare to maintain that many batteries. However, it excels for small cleanups and is an excellent complement to gas-powered blowers. Furthermore, it fits right in with commercial users already on the 56V eFORCE battery platform. I see the DPB-5800T as a solution for pros who may be hamstrung by gas-powered bans and noise level restrictions. Residential neighborhoods, large office buildings, and even interior work are all possible thanks to the quiet battery performance.

The DPB-5800T is currently available for $349.99 as a bare tool and $699.99 as a kit with two 5.0 Ah batteries. Overall I think this represents a good value, but I would prefer a kit offering with larger battery packs or even three total batteries and an additional charger. This would be a true one-stop solution for a pro user.

Follow the Buy Now link below to purchase an Echo DPB-5800T backpack blower from our friends at ACME Tool!

Echo 56V Battery Backpack Blower Review is a post from Tool Box Buzz

Best Mid-size, Rechargeable Flashlight

When it comes to choosing a flashlight, size and reliability are crucial factors, especially for those who need a dependable light source for outdoor adventures, emergencies, or daily tasks. Among the myriad of options available, rechargeable flashlights stand out for their eco-friendliness and cost-effectiveness, eliminating the constant need for disposable batteries.

In this Head-to-Head, we took a look at six, 4 to 6-inch rechargeable flashlights. We recognize that there are dozens of rechargeable flashlights available on the market, so we chose popular mid-sized, rechargeable lights in the sub $100 range.

In this article, we walk you through our testing process and explain how we selected the best rechargeable flashlight within this size and price range. We’ll highlight key features and discuss why it deserves a spot in your gear collection.

Flashlights Tested In This Evaluation

Braun 1800 Lumen Tactical Light

Model 59282
Max. Lumens 1800
IP Rating: IPX7
Material: Aluminum
Length 5.68 in.
Width .95 in.[head 1.26 in.]
Weight 0.35 lb.
Range 740 ft.
Price: $29.99

Fenix PD36R V2.0 Flashlight

Model PD 36R V2.0
Max. Lumens: 1700
IP Rating: IP68
Material: Aluminum
Length: 5.54”
Width: 1in. [Head 1.04 in.]
Weight: 5.89 oz.
Range: 1299 feet
Price: $99.95

Milwaukee USB 2,000L Slide Focus Flashlight 2162-21

Model: 2162-21
Lumens: 2,000
IP rating: IP6 Dustproof and Water Resistant
Material: Aluminum
Length: 6.6”
Width: 1.25 in. [Head 1.5 in.]
Weight: 0.57 lb
Range: 200 m
Price: $99.00

Nitecore MH12 Pro 3300 Lumen Flashlight

Model: MH12 Pro
Lumens: 3000
IP Rating: IP68
Material: Aluminum
Length: 5.45”
Width: 1 in [Head 1.2 in. ]
Weight: 2.89 oz
Range: 552 yd.
Price: $89.95

Olight Baton 3 Pro-Max Flashlight

Model: Baton 3
Lumens: 2500
IP rating: IPX8
Material: Aluminum
Length: 2.48”
Width: 1 in. [Head 1in.]
Weight: 1.87 oz
Range: 574 feet
Price: $89.99

Streamlight PROTAC HL-X USB FLASHLIGHT

Model: ProTac HL-X
Max. Lumens: 1,000
IP Rating: IP68
Material: Aluminum
Length: 5.43 inches
Width: 1 in. [Head 1.4 in.]
Weight: 5.7 ounces
Range: 330 meters
Price: $85.99

Best Rechargeable Flashlight Testing – Criteria

We performed three performance tests to evaluate these flashlights. Additional scoring categories included qualitative evaluations of ergonomics and features, size, and pricing. Lastly, we include a best-value category.

1. Submersion test.
2. Run-time test.
3. Peak Lumen test.
4. LUX Test.
5. Exterior housing temperatures – Some of these flashlights can get hot when on for periods of time.
6. Features | Ergonomics – Most of these flashlights are feature-rich. We identified, evaluated, and ranked 9 distinct categories for each flashlight.
7. Flashlight Beam Pattern – This is a subjective category where we share the characteristics of the flashlight’s beam. Because users prefer different beam patterns, we chose not to rank this.
8. Size and Weight – Size matters and weight can get cumbersome. We measured the dimensions and weight of each flashlight as tested (with Batteries).
9. Best Value – Oftentimes this category winner tends to resonate with most folks as it combines good performance and price.
10. Price – Price is always an important factor in determining which flashlight is best for you.

By following these comprehensive testing procedures, we can effectively compare and evaluate the performance, durability, and usability of each flashlight model, enabling informed decision-making for consumers and professionals alike.

Submersion Testing Procedure

Most flashlights are built to withstand heavy splashing and rain but should not be fully submerged. Waterproof flashlights, on the other hand, can resist water penetration completely for a certain period and depth.

When purchasing a rechargeable flashlight, pay attention to the IP or “Ingress Protection” rating. This rating is a two-digit code indicating the level of protection against solid objects (the first digit) and liquids (the second digit).

Solids are rated on a scale of 0 to 6, with 6 being the highest level of security, the first number corresponds to the size of particulate that is protected against. Liquids are rated on a scale of 0 to 8, with 8 being the highest. Products rated as impervious will have the highest number, but even these have limits. Manufacturers will list these limits so that consumers can make an informed decision.

We constructed a water submersion test rig consisting of a 10-foot 3-inch vertical PVC pipe that connects to a horizontal 2-1/2-inch clear PVC pipe. We placed the flashlights inside the clear pipe and slowly added water until the 10-foot pipe was full. The clear plexiglass allowed us to see the flashlight LED status. The valve on top of the clear plexiglass allows us to change out the test units without having to refill the tube.

All of the flashlights tested have some level of IP intrusion rating to prevent water and dust from harming the flashlight. The highest rating in the group was an IPX8 which certifies a 30 minute submersion at one meter (~3 feet). Our rig simulated a full ten feet of submersion which is significantly more pressure than the IPX8 level.

Water Test – WINNERS Tie: Braun, Olight and Streamlight

Among the 6 flashlights tested, Braun, Olight, and Streamlight emerged as the top performers, showing no signs of water intrusion after a rigorous 3-hour submersion test. These lights feature compressed o-rings that effectively protect their batteries and electronics.

Both the Olight and Streamlight lack external charging ports; Olight utilizes a magnetic charger, while accessing Streamlight’s battery charging port is located on the battery itself. Users are required to  unscrew the o-ring protected bezel and removing the battery. Braun’s design includes an o-ring sealed charging port accessible by partially unscrewing the bezel to expose the port.

In contrast, Fenix and Nitecore boast an IP68 rating but employ compressed o-rings and a rubber charging port cover, which likely led to water ingress. The Fenix failed after 32 minutes, and the Nitecore failed after 21 minutes in the submersion test.

Interestingly, all flashlights were inspected post-test, dried, and tested for functionality. The Fenix showed no signs of water damage and continued to operate flawlessly. However, the Nitecore exhibited water in all internal compartments and showed corrosion within a day.

The Milwaukee flashlight, with its IP66 rating and easily penetrated charging port, failed almost immediately in the submersion test. It senses when water gets into the port and shuts down. After a day or two, after drying out, it worked fine again.

Flashlight Run-time Output Procedure

A flashlight’s battery life indicates how long it can operate before requiring recharging. To assess this, we utilized the TKlamp TK2303 Light Meter to measure and document the runtime performance of each flashlight. While manufacturers provide run-time data, it’s often based on ideal conditions, which can create uncertainty about when a flashlight becomes impractical for use.

Our methodology involved not only measuring total run-time but also plotting the battery’s “ramp down” phase using the light meter. This approach allowed us to pinpoint the moment when each flashlight’s output dropped below 100 lumens, a threshold we deemed as signaling the need for recharging. During testing, all flashlights were operated at their highest continuous setting. We employed a time-lapse camera and digital clock to capture light meter readings every 10 minutes until the output dropped below 100 lumens.

The behavior of the flashlights varied during the run-time test.  Some flashlights throttled down significantly like the Milwaukee to just 136 Lumens within 10 minutes, while others remained at higher step down lumen levels.  To account for this disparity we calculated an approximate “area under the curve” or integral to find the Lumen-Hour  (lm-h) value output by the flashlight during the test.  You can think of this as an analogue to the amount of “Work” done by the flashlight.

Run-time Output Test Winner – Winner Olight

The Olight delivered a consistently strong performance, producing 3,326 lm-h maintaining over 450 lumens for 7 hours before dropping below 100 lumens. In second place, the Fenix with 2,827 lm-h maintained an average of 640 lumens for 4 hours. The Nitecore took third place with 2,537 lm-h and an average of 460 lumens over 5.5 hours.

Peak Lumen Testing – Winner Nitecore

Lumens is an SI-based measurement of luminous flux.  In simple terms its a measurement of of the total light output of the flashlight.  Specialized testing equipment is required to directly measure the lumens of a light source.

To test the lumens of the flashlights we used a TKlamp TK2303 Light meter.   This light meter has what is called an integrating sphere that works a light source diffuser to accurately measure the luminous flux regardless of differences in directional intensity.

Each flashlight was fully charged and placed into the aperture of the integrating sphere.  The lights were set to their highest output setting and the highest lumen reading after 1 second was recorded.  The results are in the table below.

LUX Procedure

What is a Lux?  A lux is a unit of measurement that measures the intensity of a light beam on a surface.  One lux is equivalent to one lumen per square meter.  In the previous tests, we directly measured the flashlight lumens with the integrating sphere in TKlamp light meter.

The lumens are the total amount of light that is being produced by the flashlight.  While Lux is the amount of light that is illuminating a surface a distance away from the light. Two flashlights with the same lumen rating may have vastly different Lux measurements depending on the focusing behavior of the lenses.  A broad diffuse beam will have a lower Lux reading than a narrow focused beam.

We used the candela sensor on our TKlamp TK2303 Light Meter to measure light intensity at a single point.   We can then use the candela reading across the beam-width and some math to determine the approximate Lux. When measuring the performance of a flashlight, it’s important to recognize that the light is not focused on a single 1-square-meter area, but is spread out.

Procedure

Record Maximum Foot-Candles:

1. Point the flashlight at the light meter and record the maximum reading in foot-candles (fc).
2. Rotate to Measure Beam Spread:
3. Rotate the Miter saw table until the sensor reads half of the maximum foot-candles (Max/2).
4. Record the angle at which this occurs (e.g., -10 degrees).
5. Continue rotating until the sensor again reads half of the maximum foot-candles on the opposite side and record the angle (e.g., +10 degrees)

Using these measurements, we calculated the beam width and the lumens. Knowing the beam width, we can calculate the area that the flashlight illuminates, to compare where the lens is spreading the lux.

LUX Test – Winner Nitecore

The winner of the Lux test was Nitecore with 1607.  This comes as no surprise given the very intense spotlight beam the Nitecore produces.  Second place went to the Fenix with 1066 and then the Streamlight with 754.

While its easy to generalize that more Lux is better, there is a nuance to the beam behavior that may be heavily influenced by user preference.  The bottom three performers in the Lux category all have very uniform beams with no intense center spotlight.  For users that prefer this kind of light [i.e. electricians, MRO and HVAC techs]  the Lux readings may have less of an impact.

Flashlight Temperature | Procedure

With the invention and ensuing widespread adoption of LED light bulbs, many homeowners have noticed the much cooler temperatures of equivalent lightbulbs.  LEDs are much more efficient at turning energy into light vs heat when compared to a traditional filament bulb.  However, this does not mean that LEDs are 100% efficient and when the power intensity is turned up enough, they can get extremely hot. We measured the external temperature of the flashlight on their highest setting and continually recorded their external housing temperatures using a Hilti thermal imager. The results are ranked with the coolest flashlights scoring top marks.

Temperature WINNER – Braun

A hot flashlight can be uncomfortable to use. The coolest-running flashlight tested was the Braun, reaching a peak temperature of 101.8 degrees Fahrenheit, followed by the Olight at 114.3°F. In third place was the Streamlight, with a temperature of 116.1 degrees Fahrenheit.
Most LEDs, components, and LED circuits are designed to withstand temperatures of 185°F (85°C) or higher without adversely affecting their lifespan or performance.

Features and Ergonomics – Winner Nitecore

Features are a critical factor in choosing a rechargeable flashlight, influencing its functionality, convenience, and versatility. Evaluating these attributes is pivotal in our assessments.

In our ranking, the Nitecore took the top spot with 13 points, closely followed by Fenix with 14 points, and Olight with 23 points. Nitecore impressed us with its intuitive design featuring a 2-button operation, 7 light modes, battery and brightness LED indicators, USB-C charging port, and tactical blip [on/off] switch. It stood out as the most feature-rich and user-friendly flashlight in our tests.

Fenix offered similar features with additional brightness levels but fell short due to the absence of battery and brightness LED indicators, which affected it’s score. Olight excelled with excellent brightness levels, a robust pocket clip, and rich feature set. However, its single-button operation and proprietary charging cord resulted in a lower ranking.

Summary of Flashlight Features

Most of these flashlights are feature-rich, below we summarized each lights features set.

BRAUN Flashlight

Best Mid-Size, Rechargeable Flashlight Head-to-Head 2024 is a post from Tool Box Buzz