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

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

Top Cordless 1″ SDS Plus Rotary Hammer | Head-To-Head

In our head-to-head comparison, we focused on 1″ SDS-Plus rotary hammers with drop motors, catering to the largest group of SDS-Plus users. These drills are widely utilized by mechanical, electrical, plumbing, and building trades for tasks such as installing 3″ drop anchors, wedge anchors, screw anchors and chipping concrete.

Why Drop Motors?

The 1-inch SDS-Plus drop motor hammers are among the most popular drills on the market due to their compact size and versatility. They offer versatility and efficiency for various applications, making them a preferred choice for many users across different industries. Despite the rise in popularity of drop motor designs, some users still prefer the traditional D-handle style for specific applications such working in concrete forms or for ceiling and floor work.

SDS stands for Slotted Drive System or Slotted Drive Shaft, it was invented by Bosch in 1975. SDS and SDS-Plus are interchangeable, SDS-Plus is a newer standard featuring 4 splines for a more secure chuck fitment.

Our Objective

For us at Tool Box Buzz, our goal is to empower you to make informed decisions when selecting the best SDS-Plus Rotary Hammer Drill.

By providing comprehensive reviews and insights into the performance, features, and usability of each rotary hammer, we hope to assist you in finding the perfect tool for your projects. Whether you prioritize compactness, power, versatility, or ergonomics, we’re here to help you make the right choice.

Cordless SDS-Plus Rotary Hammer Lineup

Eleven manufacturers have submitted 15 contenders for the 1-inch SDS-Plus category, all designed for use on their 18-volt to 60-volt cordless platforms. Not every manufacturer labels their SDS-Plus drills as precisely 1 inch, so the range of testing spans from ⅞ inch to 1-⅛ inch.

BOSCH 18v Bulldog

Model – GBH18v-24C
Voltage – 18v
Size – 1”
RPMs – 980
BPMs – 0-4,350
Blow Energy [Ft-Lbs] – 1.80
Weight – 8.7 Lbs
Price – $270.00

DEWALT XR

Model – DCH273
Voltage – 20V
Size – 1”
RPMs – 1,100
BPMs – 0-4,600
Blow Energy [Ft-Lbs] – 1.55
Weight – 7.1 Lbs
Price – $329.00

DEWALT Flexvolt

Model – DCH416
Voltage – 60V
Size – 1-¼”
RPMs – 540
BPMs – 0-4,200
Blow Energy [Ft-Lbs] – 4.5
Weight – 12.25 Lbs
Price – $499.00

FLEX

Model – FX15511A-Z
Voltage – 24V
Size – 1”
RPMs – 980
BPMs – 0-4,350
Blow Energy [Ft-Lbs] – 1.9
Weight – 9.45 Lbs
Price – $299.00

HILTI Nuron

Model – TE 6-22 DRS
Voltage – 22V
Size – 1”
RPMs – 1050
BPMs – 0-5100
Blow Energy [Ft-Lbs] – 1.9
Weight – 8.1 Lbs
Price – $434.00

KOBALT

Model – KRH 124B-03
Voltage – 24V
Size – ⅞”
RPMs – 1,400
BPMs – 0-4,500
Weight – 6.15 Lbs
Price – $99.00

MAKITA 18v LXT

Model – XRH01Z

Voltage – 18VSize – 1”
RPMs – 950
BPMs – 0-4,700
Blow Energy [Ft-Lbs] – 1.7
Weight – 7.55 Lbs
Price – $379.00

MAKITA 36v LXT

Model – XRH05Z
Voltage – 36V (18v X 2)
Size – 1”
RPMs – 1,250
BPMs – 0-5,000
Blow Energy [Ft-Lbs] – 2.2
Weight – 10.3 Lbs
Price – $519.00

MAKITA 40v XGT

Model – GRH01Z
Voltage – 40V
Size – 1-1/8”
RPMs – 980
BPMs – 0-5000
Blow Energy [Ft-Lbs] – 2.8
Weight – 9.44 Lbs
Price – $589.00

Metabo

Model – KH18LTXBL28Q

Voltage – 18v
Size – 1-⅛”
RPMs – 1,000
BPMs – 0-4,470
Blow Energy [Ft-Lbs] – 3.0
Weight – 9.8 Lbs
Price – $361

METABO HPT 18v

Model – DH1826DALQ4
Voltage – 18V
Size – 1”
RPMs – 1,050
BPMs – 0-3,950
Blow Energy [Ft-Lbs] – 1.9
Weight – 8.05 Lbs
Price – $209.00

METABO HPT 36v

Model – DH3628DAQ4
Voltage – 36V
Size – 1-⅛”
RPMs – 950
BPMs – 0-4,300
Blow Energy [Ft-Lbs] – 2.3
Weight – 9.4 Lbs
Price – $279.00

MILWAUKEE M18 FUEL

Model – 2912-20
Voltage – 18V
Size – 1”
RPMs – 1,330
BPMs – 0-4,800
Blow Energy [Ft-Lbs] – 2.0
Weight – 9.25 Lbs
Price – $349.00

RIDGID

Model – R86712B
Voltage – 18V
Size – 1”
RPMs – 1,400
BPMs – 0-5,000
Blow Energy [Ft-Lbs] – 1.5
Weight – 8.05 Lbs
Price – $269.00

RYOBI

Model – P223
Voltage – 18V
Size – 1”
RPMs – 1,380
BPMs – 0-5,000
Blow Energy [Ft-Lbs] – 1.5
Weight – 7.45 Lbs
Price – $189.00

Head-To-Head Testing Criteria

Our team meticulously evaluated these cordless SDS-Plus rotary hammers, across five categories and ranked them.

1. Performance Test – Speed at drilling various size holes in concrete.
2. Efficiency Test – Run-time test of recommended battery normalized for Watt-Hour capacity.
3. Size and Weight – Size matters and weight can get cumbersome. We measured the dimensions and weight of each concrete drill as tested with batteries. [not factored in overall ranking]
4. On-Board Dust Collection – we tested and ranked features.
5. User Experience- Combination of features, ergonomics and subjective user evaluations.
   Additionally we included price, and best value charts for your consideration.

Silica Dust

The Tool Box Buzz Team recognizes the significant dangers that exposure to silica dust can pose to workers. While we always strive to use any and all personal protective equipment, there are times when we may omit certain PPE during testing. We want to remind anyone that uses concrete cutting and drilling tools to use proper protective equipment to prevent silica dust exposure.

Performance Evaluation | Drilling Test

This test evaluated the speed in which the tools could drill 3-inch deep holes into concrete with 4 different bit sizes. The drilling substrate used was 3,500 psi concrete blocks, 12” x 24” x 4.5″ deep. These concrete blocks had cured for 6-months.

Performance Test Procedure

Drill Sizes Evaluated: ¼”, ⅜”, ½”, and 1″ SDS-Plus rotary drill bits.

1. Five holes drilled to a depth of 3” using a depth rod and blue tape for accuracy.
2. Each hole was timed, and an average recorded.
3. All drills equipped with new Milwaukee SDS-Plus rotary drill bits.
4. Operators instructed to maintain consistent pressure and let the drill do the work.
5. Dust extractors were not utilized.
6. Technique emphasized to ensure fair comparison.

Performance Test Winner – Milwaukee

Milwaukee dominated three out of the four speed tests, earning an impressive overall score of 5. DEWALT’S 60V FlexVolt secured second place with an overall score of 15, excelling particularly with the 1-inch bit test. Hilti and Ridgid claimed third place with an overall score of 18. Metabo followed with a score of 21. The Metabo was not a remarkable tool, but was a consistent “power-house performer.”

Individual Test Results | Top 3

¼” Rotary Bit Results

• Milwaukee: 4.19 seconds
• DEWALT 60V: 4.63 seconds
• Hilti: 5.49 seconds

⅜” Rotary Bit Results

• Milwaukee: 4.93 seconds
• Ridgid: 5.24 seconds
• DEWALT 20: 5.88 seconds

½” Rotary Bit Results

• Milwaukee: 4.36 seconds
• Ridgid: 5.43 seconds
• Hilti: 5.57 seconds

1” Rotary Bit Results

• DEWALT 60V: 14.52 seconds
• Milwaukee: 21.63 seconds
• Metabo: 24.04 seconds

Note on DEWALT FlexVolt 60V Rotary Hammer

The DEWALT Flexvolt was an extremely powerful and heavy tool allowing it to shine in the 1-inch drill bit test and subsequent chipping evaluation.

Efficiency Evaluation | Normalized Run-time

Although run-time becomes less critical with sufficient battery capacity, we acknowledge it’s importance in specific scenarios such as with commercial users, installing numerous drop anchors in a day. With so many tools, battery voltages and sizes, we normalized run-time and investigated the efficiency of the tools energy available. Obviously some battery packs contain much more potential energy so it’s important to try and compare them based on the “size of the fuel tank”.

Efficiency Testing Procedure

1. Vacuums removed for this test.
2. All tools equipped with fresh batteries.
3. 1/2″ Milwaukee drill bits drilled to 3″ depth.
4. Operators instructed to maintain consistent pressure and let the drill do the work.
5. The total number of drilled holes were counted and scored.

Holes Drilled Per Watt-Hour – Winner Makita 18V

The Makita 18V drill claimed the top spot, surprising us all with it’s performance. This drill managed to complete 66.5 holes with a single 4 Ah battery with a 0.92 holes drilled per watt-hour.

Interestingly, the Makita 36-volt model, despite having twice the available watt-hours, only completed 82 holes, representing just a 23% increase in hole count which equated to only drilling 0.57 holes per watt-hour. This unique comparison between the two Makita drills highlights a design prioritization of efficiency vs power.

The Metabo 18 volt came in second place with 0.85 holes per watt-hour. Third place went to the DEWALT 20 volt with 0.82 holes per watt-hour.

Size and Weight – Not Used In Final Rankings

In the realm of SDS-Plus rotary hammers, size matters to some users. We measured the dimensions and weight of each drill, as tested (with Batteries / handle), and ranked them accordingly.

We felt the two most important factors for these drills were the weight and head length. Having a lightweight tool coupled with a compact size can be an important factor for some users. While we didn’t include this ranking in the final scoring we did account for the size and weight in our user experience rankings below. It’s interesting to see that most of the smaller / lighter tools didn’t perform as well as the heavier tools in the speed testing. Likely this is due to the size of the gear boxes, motors and housings.

In this category, the Kobalt drill boasted the shortest and lightest stature among all drills tested, clinching the top spot. Following closely in second place was the DEWALT 20V, which also showcased a compact form factor and lightweight design. The Ryobi drill secured third place in this ranking.

On-Board Dust Extractor Evaluation

On-board dust extractors are designed to be used as a system. Eight of these tools were sent with compatible on-board dust extractors to evaluate.

Dust Extractor Procedure

We tested the on-board dust extractors, ranking eight criteria:

1. Capacity – We drilled ½” x 3” holes until we saw dust “ant-hills” form around the hole. At that point we consider the capacity of the dust extractor full.
2. Visual inspection of capacity.
3. Filter cleaning – Self cleaning or manual function
4. Filter replacement – ease of removal.
5. Depth of hole with attachment.
6. Depth guide – ease of adjustment.
7. Replaceable head.
8. Weight.

On-Board Dust Extractor – Winner Hilti

The Hilti came in first place in the on-board dust extractor category. It was feature rich with its replaceable head, depth guide, and filter cleaning options. Despite clinching the top position, the team collectively noted that the dust canister could be improved by being translucent for better visibility, and the filter could be easier to detach from the canister.

In terms of “capacity” performance, the Hilti canister maintained dust extraction efficiency for 14 holes. Milwaukee drilled 10.5 holes, and Makita 40V managed 15 holes.  Surprisingly, the Metabo HPT drilled 21.5 holes, and the DEWALT 20V drilled 22 holes, but didn’t excel  in other feature comparisons.

User Experience – [Tie] Winner Hilti and Makita 40V

User experience (UX) encompasses the overall satisfaction and ease of use that a tool provides to its users. In this category, our team of Pro users provided subjective rankings for the user experience while handling these rotary hammers. This ranking was based on various factors experienced, including grip, balance, vibration, line of sight, ease of use, fatigue factor, and overall comfort.

The team identified four drills as top performers during testing. The Hilti and Makita were tied for first place, closely followed by a tie between the DEWALT 20V and Milwaukee 18V. All four of these tools exhibited commendable performance in our testing and were noted for their user experience.

Rotational Force | Bind Test – Not Ranked

When a drill binds, it has the potential to violently spin the tool around potentially injuring the user.
To assess the performance in binding situations, we conducted a subjective test by drilling a 1-inch diameter, 8-inch, deep hole in concrete and side load force.

3 Types of Safety Shut-Offs in Rotary Hammers

1. Accelerometer – An electronic component integrated into the tool that detects sudden rotation and initiates an automatic shutdown.
2. Mechanical – Utilizes a straightforward mechanical clutch mechanism whereby the tool continues to run, but the bit stops spinning when the clutch is engaged.
3. Electronic Overload – An electronic overload function is activated either before the mechanical clutch or during specific binding scenarios. This electronic overload serves to safeguard the electronics, motor, and battery, while also acting as a safety feature in certain situations.

Rotational Force Findings

During our testing, all of these tools effectively shut off when the tool was bound up and the user had a firm grip on both the tool and the auxiliary handle.

Standout tools featured all three safety mechanisms, predominantly found in higher-end models such as those from Bosch, Hilti, Makita (40-volt) and Milwaukee. These tools successfully incorporated all three mechanisms that we were able to activate during field testing.

Chipping Test – Winner DEWALT 60V

Our chipping testing methodology was primarily subjective in nature. We employed our drill testing blocks to conduct the chipping tests.

TBB Crew users utilized the rotary hammers to break up the test blocks, after which they provided feedback via a form detailing their chipping experience.

The consensus from our testing suggests that there’s a “secret sauce” combination of impact energy and beats per minute (BPM) that yields optimal chipping power. This mix of factors seems to be instrumental in achieving productive chipping results.

The DEWALT 60V was the largest and heaviest tool in the group and with 4.5 FT-LBS of energy, it’s no surprise that it excelled at chipping, taking first place

The DEWALT Flexvolt was a “jack hammer disguised as a drill  ~ TBB Crew Wes Bartosik

The Makita 40V came in second. It has tons of power and minimal vibrations felt, due to its well throughout decoupling. The Milwaukee 18V came in third place. It delivers an incredible amount of energy on impact and was very controllable while cutting scribe lines.

SDS-Plus Rotary Hammer | Price – Not Included In Final Scoring

Most manufacturers offer these rotary hammers in kit form, bundling the tool with a battery optimized for performance while maintaining a manageable weight. Achieving the best user experience hinges on finding the right balance between weight, balance, and power to accomplish tasks efficiently.

For your reference, we have listed bare tool pricing below, although this wasn’t factored into our final scoring. As an illustration of the cost range, the Kobalt is available as a bare tool for $99.00, while the Makita 40-volt model is priced at $589.00. Please refer to the attached chart for further details.

Best Cordless 1-Inch SDS-Plus Rotary Hammer – Winner Milwaukee 18V

While impact energy undoubtedly influences a tool’s performance, it’s crucial to recognize that it’s not the sole determinant of effectiveness. Other factors, such as RPM and BPM, also play significant roles in achieving the desired outcome for the user. Harmonizing impact energy, RPM, and BPM is essential to optimize the tool’s overall efficiency and effectiveness.

Decisions should be based on considerations related to ergonomics, safety, and mechanical performance. Balancing these aspects ensures that the tool not only performs well but also prioritizes the safety and user experience of the user.

It’s noteworthy that when ranking our categories, we assigned double weight to performance scores, considering it the most valuable category.

Milwaukee claimed the top spot in performance, secured second place in dust extraction, and ranked third in both user experience (UX) and chipping. Its overall performance stood out as the clear winner.

Second Place honors go to the Makita 40V.  This Makita excelled in UX, chipping and dust extraction. The Makita 40V was a favorite among the crew, tying with Hilti for the top spot in UX.

Hilti rounded out the podium in 3rd place.  The Hili was also heavily sought after by the crew and ranking first in the UX category, boasting the best dust extraction, and coming in eighth in performance testing and fourth in chipping.

Tied for fourth place was Metabo and DEWALT 60V. Metabo stood out with it’s second place in efficiency and scored well in both user experience and chipping. The DEWALT 60V was impressive in the chipping tests and performance.

Best Value 1″  SDS-Plus Rotary Hammer – Winner Ridgid

This category winner often strikes a chord with users as it showcases an SDS-Plus drill that performs admirably while being more budget-friendly. In many respects, it’s a category of significant importance, sometimes overshadowing the top-ranked contender, crowned king of our 1″ SDS-Plus Rotary Hammer Head-to-Head Test.

The Ridgid 18V, priced at $269 as a bare tool, claimed victory in this category. Despite landing in seventh place overall, it delivered commendable performance, securing a solid fifth place rank in our performance testing. We often refer to Ridgid as the “hidden gem” of the tool industry.

Best 1″ SDS-Plus Rotary Hammer | Closing Comments

1″ SDS-Plus rotary hammers are essential tools for contractors seeking efficient, versatile, and reliable solutions for drilling and hammering tasks in concrete and masonry materials.

We often receive inquiries about our final rankings and understand that there are numerous ways to compare tools.

Our primary goal during testing is to attain repeatable and consistent results. We make sure to share all the data from our tests so that users can re-rank the tools according to their preferences. If there’s a specific aspect you don’t find relevant, feel free to remove it from the matrix above and re-evaluate the rankings accordingly.

We hope you find this Head-To-Head comparison useful when considering the purchase of a 1″ cordless SDS-Plus rotary hammer. Please take a moment to explore our other Head-to-Head tests at ToolBoxBuzz.com.

Thanks, “the TBBCrew.”

Best 1-inch SDS-PLUS Rotary Hammer Video Review

Best Cordless 1 Inch SDS Plus Rotary Hammer – 2024 is a post from Tool Box Buzz

The Best “Carpenter” Sawhorse 2024

I feel like I’ve been on a quest my entire career as a carpenter to find the unicorn of sawhorses. By that I mean a pair of sawhorses that stores well, are durable, open easily, support a lot of weight, and don’t break after 2 months or immediately after dropping them on a cold day. I know I’m asking for a lot, but someone, somewhere must make that unicorn sawhorse.

Up to this point my FAV sawhorse was the DeWalt “Work Stand” aluminum sawhorses and also the not-so-cheap, plastic, “Stanley-Style” folding sawhorses.

The DeWalt has everything I need in a sawhorse, except it’s a little heavy and is super bulky to store. The Stanley plastic sawhorses are light and slim, store great, but don’t last more than a month or a single drop in cold weather.

Thus, I embarked on a systematic journey, rigorously testing various sawhorse models across my job sites over the course of six months. This pursuit proved more challenging than anticipated. With each trial, I hoped to unearth that rare gem, the unicorn sawhorse, that would surpass all expectations and become the cornerstone of my carpentry endeavors.

In the end, I tested eight different sawhorses, all different styles to determine which one best suited my needs and performed effectively on the job site. The sawhorses included were:

1. Bora Workhorse XT
2. Central Machinery Sawhorse
3. Dewalt Heavy Duty Work Stand
4. Dewalt Adjustable Legs Sawhorse
5. Dewalt Metal Folding Sawhorse
6. Fulton StableMate Sawhorse
7. Kreg Track Horse
8. Stanley Folding Sawhorse

I evaluated these sawhorses based on six criteria to determine the best option, considering:

1. Weight
2. Storability
3. Durability
4. Set up and break down (Ergonomics and functionality)
5. Additional features
6. Cost

Note: All the sawhorses in this test had to have a capacity of at least 1000 pounds or more, as anything less wouldn’t meet the standards of a job site quality sawhorse. Moreover, a higher weight capacity typically indicates better structural integrity and durability.

BORA Workhorse XT

The BORA Workhorse XT stood out with its pre-drilled end brackets and a top beam that facilitate the creation of a sacrificial top and the attachment of 2×4 materials, enabling the assembly of a sturdy workstation.

Specifications

• Material:     Steel
• Height:        Adjustable 30 inches to 34 inches.
• Length:       38
• Depth:         4.5
• Weight:       15 lb.
• Capacity:     1,350 lbs. each [2,700 pair]
• Cost:           $ 160.00 [pair]

Observations After Using

Build quality of the BORA Wokhorse XT sawhorse was clearly engineered for durability and reliability. Key features include a weight capacity of 1,350 lbs. per sawhorse, totaling 2,700 lbs. per pair, ensuring ample support for storing stock.

The Bora’s height can be adjusted from 30 to 34 inches in 1-inch increments using an intuitive lever and slide and lock technology, catering to differing user heights or needs. Because the 2×4 slots stick out on the ends of these saw horses you will either love or hate them. I loved them – and we found them study and strong.

Additionally the top is set up for attaching a sacrificial board, and when combined with the side supports you can make a quick and easy support table,

There was a lot to like about the Bora sawhorses, they’re light, super strong, compact and well built. There were two things I did not like about them; you are required to fold one side of the legs first or they will not fold and store properly. The second issue I had is that they do not latch together and for storage.

Central Machinery 30 in. Steel Folding Sawhorses

The Central Machinery 30-inch Steel Folding Sawhorses, sold in a 2-pack, offer robust support for and impressive 2,000 lb. weight capacity.

Specifications

• Material:     Steel
• Height:        30 in.
• Length:       32 in.
• Depth:         5-1/2 in.
• Weight:       16.4 each
• Capacity:     2,000 lbs.
• Cost:           $40.00 pair

Observations After Using

This saw horse features a folding design. Their MDF tops are well-suited for saw cuts, providing a stable work surface. Additionally, the inclusion of a metal crossbar ensures the legs remain securely locked during use, enhancing strength and stability. However, assembly is cumbersome, likened to an “IKEA-like setup,” which is time-consuming and less than enjoyable.

To improve the top of these sawhorses, I utilized a router to round over the sharp edges on the MDF tops, adding a finishing touch to their design.

Upon using the Central Machinery sawhorses, I promptly recognized their difficulty in storing efficiently. Additionally, I observed that the plastic feet on the bottom of the legs tended to detach easily. To address these issues, I took the initiative to wrap the feet in electrical tape, providing a quick and effective solution for enhanced stability and storage convenience.

While these sawhorses deliver reliable performance, at an affordable price point, they don’t meet my needs, and I think they are best suited for DIY enthusiasts.

DEWALT Heavy Duty Work Stand DWX725

As I mentioned in my opening paragraph, up to this point these are the best saw horses that I’ve used, but they take up too much space! The DEWALT Heavy-Duty Work Stand, is built from corrosion-resistant aluminum, offers a reliable solution for storing stock, supporting a standing planks or a sturdy work table

Specifications

• Material:     Aluminum
• Height:         32″H
• Length:       ‎36″L
• Depth:         ‎11″W
• Weight:       15.4 lb.
• Capacity:     1,000 lbs. each [2,000 lbs. pair]
• Cost:            $200 pair

Observations After Using

With a maximum weight capacity of 1,000 lbs. each, this stand accommodates various materials effortlessly. Its lightweight design, weighing only 15.4 lbs., ensures easy transport. Additionally, the stand’s legs lock securely into place, providing dependable stability as you work. The legs feet are large, non-,marring and securely fastened to the legs.

It’s transport latch ensured that both units stay together during transport or storage. When carried separately they have the best carry handle of all the saw horses. When latched together, there is no handle.

My favorite feature on these sawhorses are the leg lock levers which allow easy set up and storage. My least favorite featured is the bulkiness and overall weight of the pair carrying them,  and they take up too much space to store. They also do not like how they adjust in height.

It also accepts optional DW7231 miter saw mounting brackets allowing use as a tool stand. Overall, the DEWALT Heavy-Duty Work Stand combines durability, portability, and safety features to support a wide range of tasks for pros. If you have a lot of of storage space, a box truck or trailer, you cant beat these saw horses.

DEWALT Adjustable Legs Sawhorse

The DEWALT Adjustable Legs Sawhorse combines durability, versatility, and ease of use to provide reliable support for various tasks.

Specifications

• Material:     Steel, Aluminum, Plastic Polymer
• Height:        32.7 in
• Length:       27.2.
• Depth:         2.2 in.
• Weight:       14.17
• Capacity:     2,500 lbs.
• Cost:           $ 70 pair

Observations After Using

Crafted from a high-quality combination of steel, aluminum, and plastic polymer, it boasts a remarkable load capacity of up to 2,500 lbs. per pair. I liken this sawhorse to the Stanley sawhorse, only on steroids!

It has a yellow slide lever that allows easy adjustment of legs separately, catering to uneven surfaces with clear, large numbers indicating height settings.  The legs have rubber feet, and the working bar has a V groove ruler for working with lumber or pipes.

Taller users will appreciate the back-saving adjustable height legs.  While these saw horses are somewhat heavy, their durability and load capacity make them suitable for heavy-duty tasks. Unlike cheaper alternatives, they remain stable under pressure and do not fold up or collapse unexpectedly.

I liked the adjusting height, folding mechanism and lightweight design of these saw horses. Despite its ruggedness and lightweight design, we experienced issues with the top brackets designed to hold 2x4s, which broke early on after being deployed to our cold job site. This was a huge bummer because I had such high hopes for this set.

Overall, the DEWALT Adjustable Legs Sawhorse is recommended for those seeking a robust and reliable work support solution for pro users. At the end of all the testing Dan, our lead carpenter chose these  horses for his van. Dan’s favorite sawhorse was the Kreg Workhorse, but his reasoning for choosing the DEWALT was they fold flat and were the easiest to store in his van.

“When you think about it these sawhorses live in the van more then they are set up, I want them to store neatly “~ Dan Shaw

DEWALT Metal Folding Sawhorse

The DEWALT Metal Folding Sawhorse features a robust metal structure designed to hold up to 2000 lbs. as a pair.

Specifications

• Material:     Metal, plastic
• Height:        10.686 in
• Length:       32 in.
• Depth:         4.68 in.
• Weight:       11.8
• Capacity:     2,000 lbs.
• Cost:           $ 80 pair

I liked the two top metal bars which facilitate secure clamping, easily accommodating trigger clamps. Its quick and compact folding capability ensures portability and easy storage, while features such as anti-slip pads on the top and legs enhance stability during use.

Observations After Using

These sawhorses offer exceptional versatility, including a 2×4-inch notches for creating a work station and a large V-groove ideal for handling pipes.  There is no option for mounting a sacrificial board without modifying and drilling the metal bars. At the end of this testing there was a saw kerf in the top rail from someone cutting too deep.

In the center of each sawhorse is a yellow flip handle that facilitates effortless carrying, while yellow side latches enable the convenient securing and transportation of two sawhorses together. While using we noted that the plastic locks popped off once and was reattached, it does seem likely to break over time.

I really liked using this set, in fact, its still in my work van being used. I like its lighter weight, carrying handle and overall compact size for storage.

Fulton StableMate Folding Professional Grade Sawhorse

The Fulton StableMate Folding Professional Grade Sawhorse is a testament to quality craftsmanship, proudly manufactured in Fulton, IL, just two hours west of Chicago along the banks of the Mississippi River. Crafted from robust 16-gauge steel, these American-made sawhorses are way  heavier than the competition, but their durability is unmatched, providing peace of mind for daily use.

Specifications

• Material:     USA Grade Galvanized Steel and welded tubing steel
• Height:        30 in.
• Length:       42 in.
• Depth:         5-1/2 in.
• Weight:       39 lb.
• Capacity:     3,000 lbs.
• Cost:           $ 200 pair

Observations After Using

We were impressed with the galvanized construction, eliminating concerns about leaving them outdoors and exposed to the weather.  Lets face it many sawhorses spend their entire life outdoors. We only set these sawhorses up once and they sit stationary with a pile of material on them. I forgot to get a photo of them, these are stock photos from the company website.

PHOTO: Leg Hinge

The StableMate’s folding legs are solid and have a beautify designed hinge mechanism. The legs lock open and fold and lock closed for convenient and compact storage. The only negative I found with them was that you have to fold one side of the legs first or they won’t fold tightly.

The non-skid rubber feet are solidly made and secured in place. With heavy-duty construction at its core, the Fulton StableMate offers reliable heavy material support.

My impression of these sawhorses is that they are built to last 100 years. Their construction feels robust, almost like diesel-powered.

The fact that they are made in the US, which is a big plus for me. However, they’re also quite heavy, which isn’t what I’m looking for in my daily tool setup. That being said, I’ve found the perfect application for them: they now serve as my material delivery sawhorses, since they can easily hold a pallet of plywood on them.

Bottom line – I was impressed with the build quality, durably, and 3,000 lb. weight capacity. Kudos to you Fulton!

KREG Track Horse

This sawhorse was a crew favorite.  Crafted from steel, aluminum, and plastic polymer, it offers durability and stability for various tasks.

Specifications

• Material:     Steel, Aluminum, Plastic Polymer
• Height:        30 in.
• Length:       42 in.
• Depth:         5-1/2 in.
• Weight:       24 lb.
• Capacity:     2,200 lbs. (997 kg) per pair; 1,100 lbs. (498 kg) individually
• Cost:           $ 360 pair

Observations After Using

The Kreg Track Horse is feature-rich and can be used as a work table and clamping system, not just a saw horse. The Track Horse boasts an impressive weight capacity of 2,200 lbs. per pair ensuring reliable support for heavy materials if needed.

One of its standout features is the dual-mode clamping system, which enables secure holding of work pieces using either the long track on top, or keyhole brackets on the ends, for vise-style clamping. Each Track horse comes with one Kreg Bench Clamp.

One feature I wasn’t particularly enamored with is the side support bracket clips designed to hold 2x4s. While I’m a fan of the 2×4 support, Kreg designed these clips to easily remove to allow access on the side for the Bench clamp. My issue is that there is no good place to store these clips, and I absolutely see them getting lost. I would prefer to have some sort of onboard storage option for them.

The Kregs top track design accommodates sacrificial surfaces, allowing for cutting without damage. Its adjustable legs offer six working heights, ranging from ground-level use with folded legs, to various elevated positions. A large lever unlocks the legs to unfold, or fold for easy storage and transport.

Because these sawhorses are robustly made, they’re large. They also do not latch together or have a carry handle.

Overall, we really like the Kreg Track Horse. It combines versatility, durability, and innovative features to provide a superior work support solution for professionals. However, its higher price point of $179.00 may be considered a drawback for some.

Stanley Folding Work Bench Sawhorse

The Stanley Folding Sawhorses and many other similar, folding sawhorses I have used are the OGs on the job site. They all boast a polypropylene construction and I have always been amazed that they have a capacity of 2,700 pounds as a pair.

Their design includes a V-grooves for secure material placement and clamping, along with top rubber pads to prevent slippage. I’ve been using  sawhorses like these for years because they are so light and easy to transport. I also like that they fold and store easily – but they don’t hold up to the rigors of the job site.

Specifications

• Material:     Polypropylene
• Height:        32.09
• Length:       27.28
• Depth:         4.13
• Weight:       12.6 lb.
• Capacity:     1,350 lbs. each [2,700 pair]
• Cost:           $ 44.00 pair

Folding sawhorses like these come equipped with a tool tray for storing power and hand tools, as well as a side cord hanger feature. We constantly see this tool trays break.  In fact they break too easily, which then causes the sawhorses to collapse under heavier weight. Additionally, the plastic material becomes brittle in cold weather, making it susceptible to damage if dropped.

Best Overall: BORA Workhorse XT

The BORA Workhorse XT stands out as the best overall sawhorse due to its robust construction, adjustable height, and impressive weight capacity of 1350 lbs. per sawhorse, totaling 2700 lbs. per pair.

Engineered with pre-drilled end brackets and a top beam, it offers exceptional versatility for creating a sturdy workstation. Additionally, its intuitive slide and lock technology allow for easy height adjustment from 30 to 34 inches in 1-inch increments, catering to user needs. We felt the BORA Workhorse XT delivered professional-grade expectations for performance and durability, making it the best overall sawhorse for Pros.

Best Bang for the Buck: Central Machinery 30 in. Steel Folding Sawhorses

The Central Machinery 30-inch Steel Folding Sawhorses offer excellent value for money with their sturdy steel construction, 2000 lb. weight capacity, and affordable price of $40.00 for a 2-pack. While assembly may be cumbersome, their folding design and MDF tops make them practical for various workshop tasks. Despite their lightweight design of 16.4 lbs. each, they provide reliable support and stability, making them a cost-effective choice for those on a DIY budget.

As a Pro user the best bang for the buck would be the BORA Work Horse.

Best Light-Duty: Dewalt Metal Folding Sawhorse

The DEWALT Metal Folding Sawhorse excels as the best light-duty option, featuring a durable metal structure with a capacity load of 2,000 lbs. Designed for versatility, it includes a 2×4-inch recess and V-grooves for handling various materials. Its compact folding capability and lightweight design of 11.8 lbs. make it portable and easy to store. Despite potential issues with the plastic locks over time, its affordability at $79.94 and functionality make it ideal for light-duty PRO tasks.

Best Heavy-Duty: Fulton StableMate Folding Professional Grade Sawhorse

The Fulton StableMate Folding Professional Grade Sawhorse takes the top spot as the best heavy-duty sawhorse, boasting a weight capacity of 3000 lbs. Crafted from robust USA Grade Galvanized Steel, it offers unmatched durability and stability for demanding job site conditions. While heavier at 39 lbs., its reliability, non-skid rubber feet, and built-in leg locks ensure safe and secure operation, making it the preferred choice for heavy-duty tasks.

Both the BORA Work Horse and the DEWALT Work Stand are sturdy and support a lot of weight as well. The Fulton holds the most weight of the pack!

Best Workstation: Kreg Track Horse

The Kreg Track Horse was a team favorite and stood out as the best workstation, providing a versatile and sturdy work support system for various applications. With a weight capacity of 2,200 lbs. per pair or 1,100 lbs. individually, the Kreg Track Horse offers users plenty of support and stability. Its dual-mode clamping system, sacrificial surface compatibility, and adjustable legs cater to diverse project needs. Although priced at $179.00 each, its innovative features and durability make it an excellent investment for professionals requiring a reliable sawhorse, or workstation.

Most Portable: DEWALT Adjustable Legs Sawhorse

The DEWALT Adjustable Legs Sawhorse earns the title of the most portable sawhorse, combining durability and versatility in a lightweight design. Weighing 14.17 lbs. and featuring adjustable legs for uneven surfaces, it offers ease of transport and setup. Despite potential issues with the top brackets, its back-saving adjustable height legs and compact folding design make it suitable for on-the-go professionals and DIY enthusiasts seeking portability without sacrificing performance.

Which One Did I Pick?

This evaluation has provided me with valuable insights into the variety of options available for sawhorses. Previously, I had been accustomed to purchasing cheap plastic Stanley sawhorses due to their lightweight and portability. However, I now understand that this initial cost-saving approach led to frequent replacements, costing me approximately $140 annually. Recognizing the value of investing in a better-built sawhorse upfront, I anticipate fewer replacements and less frustration in the long run.

In the end, I opted for the DEWALT metal folding sawhorse and my Lead carpenter opted for the Kreg Track Horse but later reverted to the DEWALT Adjustable Leg folding sawhorse because it stored better in his van, It’s important to note that these are our everyday grab-and-go units for our vans. We both agreed that the Fulton StableMate and DEWALT Work Stand will be our long term material platform. We also agreed that if we were setting up a long term clamping station, router table or assembly table we’d reach for the Kreg workhorse and use them.

Conclusion

When selecting a sawhorse, it’s essential to consider factors such as portability and storage convenience. For those requiring mobility and versatility, sawhorses with folding legs are ideal.

Moreover, the material of the sawhorse significantly impacts its weight and thus its portability. While ABS or plastic sawhorses offer lightweight options, steel folding sawhorses are sturdier but heavier. Heavy-duty models with high-capacity clamps may be more cumbersome to move, so it’s essential to balance weight with durability based on individual needs.

Additionally, considering additional features can enhance functionality and efficiency. Sawhorses with built-in shelves, cord hooks, or clamps provide added convenience for various projects, offering a versatile tailored worktable.

In essence, the decision to invest in a quality sawhorse should be guided by considerations of mobility, durability, and additional features, ensuring optimal performance and longevity for whatever you put it through.

Sawhorse Head-2-Head comparison

Best Sawhorse Head-To-Head is a post from Tool Box Buzz

Best Battery Powered 14″ Concrete Cutter (Cut-Off Saw) | Head-To-Head

A Concrete Cutter sometimes called a cut-off saw, masonry saw, road saw, “consaw,” or concrete saw is a hand-held tool designed to cut concrete, asphalt pavement, rebar, steel and plastic pipe. Typical uses include making openings in walls, floors, manhole structures, road surfaces, and curbs.

We all recognize that battery-powered saws require less maintenance, are easier to start, and forgo the need for the 50:1 fuel mixture.

Our industry is now experiencing an increased focus on the integration of battery-operated equipment across the job site, driving the discussion of gas tools vs. battery-powered tools. For us to even have this conversation we need to agree battery tools need to compete with gas in performance, power, and run-time.

We decided to perform a Head-to-Head test on four cordless concrete cutters (cut-off saws) to determine which one was the best saw and if these saws could compete with gas saws.

To give clarity to our testing we included the Husqvarna K770 gas saw, as a comparison standard.  Husqvarna has been making cut-off saws since 1958, and we chose the K 770 because it is a powerful, all-around concrete cutter with features that make it one of the best saws on the market.

Cordless Cut-Off Saw | Line-Up

Four manufacturers sent their cordless cut-off saws and saw blades.

NOTE – The Hilti cut-off saw is a 12″ saw but was allowed to participate in this test because it has a feature called OutCut, which allows it to cut at similar depths as the other three 14″ saws. To understand what OutCut is, the arm of the saw narrows to a smaller point compared to other saws and uses a smaller diameter flange-set for use with steel core diamond blades.

Hilti

• Model – DSH 700-22
• Max Cutting Depth – 4.75″
• Weight w/ battery provided – 31.0 LBS
• RPM – 5,080 RPMs
• Blade Size: 11-13/16
• Blade:  Hilti 12″ Equadist SPX 22-87947
• Battery Watt Hours – 255Wh x 2 batteries = 510 Wh

Husqvarna

• Model – K1 Pace 14″
• Max Cutting Depth – 5-5/8″
• Weight w/ battery provided – 30.8lbs
• RPM – 3,400 RPMs
• Blade Size: 14″
• Blade: S35S 14-inch Segmented Diamond Blade
• Battery Watt Hours – 749 Wh 
  

Makita

• Model – GEC01PL04
• Max Cutting Depth – 5″
• Weight w/ battery provided – 34.25 LBS
• RPM – 5,300 RPMs
• Blade Size” 14″
• Blade: 14″ Thin Kerf Diamond Blade Segmented General Purpose
• Battery Watt Hours – 288 Wh x 2 batteries = 576 Wh

Milwaukee

• XF315-2XC
• Max Cutting Depth – 5″
• Weight w/ battery provided – 33.35 LBS
• RPM –
• Blade Size: 14″
• Blade: Diamond Ultra 49-93-7540
• Battery Watt Hours – 576 Wh
  

Our Testing Criteria

Our team scored the cordless cut-off saws on eight criteria, each ranked independently, and the “Overall Best Cordless Cut-Off Saw” was determined using the combined test results.

We include but did not rank Watt-Hours Per Cut, and Best Value categories, but list them here for your own informational purposes. We did NOT include decibel testing since all of these saws are well over the OSHA rating for hearing protection.

Scoring Criteria – Cordless Cut-Off Saws

1. Concrete Cutting Test – Most lineal feet cut in concrete with embedded rebar [Ave. speed]
2. Rebar Cutting Test – Fastest cutter of five ganged #4 rebar. [Ave. speed]
3. Watt-hour per cut – we include this for your reference
4. Depth of Cut – Saws were ranks for cut capacity
5. Charging Time – We ranked the time it took to charge depleted batteries.
6. Ergonomics – Ergonomics is really important to users and an important category to consider when purchasing any power tool.
7. Features – We discuss stand-out features and team favorites
8. Size and Weight – Size matters and weight can get cumbersome. We measured the dimensions and scored weight of each concrete cutter as tested (with Batteries)
9. Best Value – Not ranked.
10. Price – The kit price at the time of publishing.

Concrete Test Blocks

We poured 3,500 psi concrete blocks, 12” x 24” x 4.5″ deep. We made the blocks deep enough for all cutter blades to be able to cut all the way through and allow ¼” for any blade wear.  Each concrete block also had two embedded # 4 rebar running along its length. 

Performance Testing  | Concrete with Embedded Rebar Cutting [Ave. Speed]

Each cordless concrete cutter was outfitted with a fresh battery and manufacturer specific blade. All of the manufacturers insisted on us using their branded blades with their saws, claiming that the blades were designed and optimized for the saw.

Run-time on cordless cut-off saws is important when discussing how battery and gas operate differently.  The number one question we are asked is,  “How do these saws compare to a gas concrete cutter? In order for us to address this question we included the  Husqvarna K770 gas saw as a comparison.

Run-time Test Procedure:

Without a test rig to eliminate these types of variables, it is very hard to have a controlled test. Technique is important and we recognize that we needed to let the tool do the work and not bog it down, which is why we designed our tests with the following criteria:

1. All 4 battery saws had two sets of fresh batteries and new Manufacturer blade.
2. The Husqvarna K770 had a full tank of gas and a fresh Milwaukee Diamond blade.
3. 4 operators per saw.
4. We used the 24″x12″x4.5″ concrete test blocks.
5. Each cut was timed and recorded.
6. Water was used on each cut.
7. Each operator made 3 cuts and swapped out to prevent fatigue. [Fatigued users tend to lean on the saw]
8. Every operator employed a “stepped” cutting method.
9. Every operator let the tool do the cutting, and listened to the motor for feedback. Operators applied pressure when the tool would allow it, and if the motor seemed like its bogging down they let up on the pressure.
10. The test ended when the saw battery died, and when the K770 ran out of gas.
11. The total slices [including partial cuts] were recorded for a total lineal foot measurement.

Note – The Husqvarna K770 gas saw has a fuel tank capacity of 0.95 qt.

Note on Step Cutting:

Step Cutting, also known as incremental cutting, involves making multiple incremental cuts with the saw until the overall desired depth of cut is reached. The number of cuts taken to reach the desired depth depends on the material being cut, the saw’s horsepower, and the operator’s experience.

• Step Cutting Increases Cutting Efficiency
• Step Cutting Increases Blade Life
• Step Cutting Results in Cleaner, Straighter Cuts

Note on Run-time Testing

With any cut-off saw you will experience varying results based on the material you’re cutting, you’re cutting style, operator experience, blade used, etc.  Ambient temperature also affects run-time. The more demand you put on the motor, for example leaning into the saw too much, the more Amps it will pull from the battery to keep the power output. The same effect can happen with a gas saw, except run-time is just not usually taken into consideration given the quicker refueling vs. recharging time.

Run-Time Testing | Winner –    Husqvarna

In all cases, it is necessary to supply two sets of batteries in order to compete with the expected run-time of a single tank of gas, on a gas saw. Manufacturers recognize this, and most are starting to sell these saws as a kit with two sets of batteries

The Husqvarna concrete cutter was able to complete 36 cuts, or 36 linear feet, in the concrete blocks, compared to the K770 gas saw which completed 30 cuts (30 linear feet). Second place was the Hilti cut-0ff saw with 29 cuts (29 linear feet), followed by the Makita with 24 cuts (24 linear feet) and Milwaukee with 23.5 cuts (linear feet).

One interesting fact was the average speed to complete these cuts.

The gas K770 saw completed 30 cuts  [30 lineal feet] with an average speed of 35.5 seconds.  The Milwaukee which brought up the rear with the least amount cut, was powerful enough to cut the concrete blocks even faster than the gas saw at 34.9 seconds.   The Husqvarna cut an average of 40.7 Seconds and both the Hilti and Makita tied with 45 seconds.

Note – photos in this article show K1 Pace with a smaller battery. This saw was photographed, and tested with a smaller battery, and later that week, tested again with a larger battery. The stats in this article are from the larger battery.

Watt-Hours Per Cut

While many sectors of the power tool industry have transitioned to battery power and cut the cord, there remains some specific tools like cut-off saws (concrete cutters) where there is no cord to cut.  Instead the power source is a small engine that runs on gas.  In order for the cordless cut-off saws to compete with the gas power standards, they need to not only have similar cutting power but also carry enough potential energy on board to get the job done. 

With all the tools running at different voltages, the quickest way to get a snapshot of how big a “gas tank” the tool has is to see how many Watt-Hours the batteries on board have.  We ran our endurance test with one battery swap so Watt-Hours are doubled in the chart.  By calculating Watt-Hours per cut we can get a good idea of how efficient the tool is at transforming that battery potential capacity into concrete cut. 

The Husqvarna had the largest battery of the group which helped it achieve top rank of cuts.  But it was also the second most efficient at using its “gas tank.” The Hilti had the least amount of Watt-Hours but cut the second most amount and was a standout as the most efficient with 35.17 Wh/cut.

The Makita and Milwaukee have exactly the same Watt-Hours on board and cut almost an identical amount concrete.  The Makita edged out a half cut over the Milwaukee which translates to a lower Wh/Cut value of 48.00.

An interesting observation when comparing the efficiency ranking of the tools is to compare them to the following speed and power rankings.  It’s clear there are always design tradeoffs between power and efficiency and these tools are no exception.

Performance Testing  |  Rebar Cutting [Ave. Speed]

Each cordless cut-off saw was outfitted with a fresh battery and the same brand specific abrasive cutting disk. One operator was used to make three cuts in five ganged #4 rebar for an average time.

Speed Test Procedure:

1. The same operator and timer teamed up to make 3 through cuts in five #4 rebar.
2. Each cut was timed separately.
3. The operator pushed as hard as the saw would allow.
4. The three cuts were averaged and scored.

Fastest Rebar Cutting |  Winner – Milwaukee

The Milwaukee was able to cut through five #4 rebar in. 7.78 seconds. Second place was the Makita at 10.3 seconds, and third was Husqvarna at 16.4 seconds, Hilti fourth at 17.0 seconds.

The team felt that this test, with all of the saw using an identical blade, was a great indicator of the available cutting power.

Depth Of Cut | Winner – Husqvarna

The depth of cut on a saw is important to all users. Husqvarna had the deepest depth of cut with 5-5/8 inches. Second place was the Makita and Milwaukee both with 5 inches, followed by the smaller Hilti saw at 4-3/4″. Husqvarna’s unique design where the arbor is offset from the drive band allowed for this impressive cutting depth.

Power Cutter Ergonomics | Winner – Husqvarna

The ergonomics evaluation in this section is purely subjective and based on the opinions of the testing crew. After a full day of running performance tests, the team sat down and ranked each tool in several categories on a score of 1-4 [1 being the best]. For the ergonomics evaluation, the team evaluated the following criteria:

1. Grip
2. Balance
3. Line of Sight
4. Vibration
5. Blade change
6. Battery change

The Husqvarna was the clear winner and a team favorite with final ergonomic score of 9. It won three categories with top score for grip, balance and line of sight.

The team did not like that the Husqvarna does not have rollers but all agreed that it had excellent vibration damping, excellent balance, was the smoothest cutting and its streamlined design contributed to its excellent line of sight. It was very obvious to the team that Husqvarna has been making these cutters for a long time, and the form factor of their battery powered and gas powered saws is very similar.

Second in ergonomics was a tie between the Hilti and Milwaukee. Hilti took tops in vibration, and scored second in balance. Milwaukee came in second in grip, line of sight and blade change.

The team liked the Hilti grip and balance and felt it had a really good line of sight. All of us felt that it was a smooth cutting saw  and was one of the easiest saws to start and operate. The only criticism was that the batteries tucked under the tool and are not as easy to insert or remove compared to the others.

Milwaukee is a powerful cutting saw that you can lean on. It has a nice grip, excellent line of sight, great balance, good battery removal but is a bit bulky and heavy.  The Milwaukee saw has no visible decoupling  but had surprisingly low vibration. Milwaukee does isolate the drive systems gear box to minimize vibration.

Makita which scored tops in blade change and had very easy battery changes. However its bulky size, weight, and uneven balance hindered its ergonomics score. The Makita had the easiest blade change, was a super powerful saw, it was the only saw that you never had to back off on while cutting.

While cutting concrete the Makita seemed to vibrate quite a lot. However when more force was applied the vibration lessened considerably. Basically the user was forced to “preload” the decoupling spring to prevent blade chatter. This seemed to be a non-issue in rebar cutting and led us to wonder if it was due to the blade more than the saw itself.

Cordless Concrete Cutter Features | Winner – Hilti

We considered 8 features on these cut-off saws:

1. Tool Activation
2. Water connection
3. Decoupling [vibration]
4. Blade Brake
5. Wheels
6. Handles [Multiple Hand Placement]
7. Indicator Light
8. Arbor Lock
9. LED Light

Hilti took first place in features with a top score in tool activation, blade brake, had the best wheels, and second best water connection. Second place went to the Makita with a well designed arbor lock, water connection and the only saw to feature an LED light. Third place in features was a tie between Husqvarna and Milwaukee.

Husqvarna has an electronic brake called “X-Halt,” which  stops the blade in a fraction of a second if a kickback occurs. The function cannot fully prevent personal injury from a kickback, but it decreases the risk.

Husqvarna had the most informative user interface, great decoupling and tool activation.  It will also time out [turn off] after 3-minutes, a time period we feel is too short.

Makita had the best auxiliary handle in terms of the amount of usable space or hand positions. It is also the only tool in the test to feature a push-button arbor lock.

Makita is equipped with “Active Feedback-Sensing Technology,” which electronically turns off the motor if the rotation of the cutting wheel is suddenly forced to stop. It also features Extreme Protection Technology, which is engineered for improved dust and water resistance.

No one on the team liked how the Makita lock-off button is actuated. This single-sided safety switch  [set up for right-hand thumb] is difficult for left-handed users to activate. Instead of a safety switch integrated into the palm grip which naturally gets depressed when holding the tool the users must push this button with their thumb 90 degrees offset to the spine of the tool. It’s neither intuitive, nor comfortable to actuate, and we all fumbled with it.

Milwaukee had a fantastic blade brake, and incorporates their RAPID STOP technology to help prevent damage from kickbacks and unexpected handling behavior. It has a unique trigger activated water valve which turns on or shuts of the water with the trigger.  This initially received high praise from the review team but later in testing proved to be a hindrance due to erratic behavior likely due high water pressure.

The Milwaukee states in the manual that the MAX water pressure for the tool is rated for 60 psi. We measured 97 psi at our test site. Milwaukee needs to address this, as contractors do not want to add an additional accessory, like a pressure reducer, to their set up.

Bluetooth Functionality

Husqvarna has built-In connectivity for asset management, allowing you to monitor location, run-time, service intervals and receive wireless updates.

Milwaukee has One-Key connectivity which allows for fleet management, location tracking and lockout.

Power Cutter Weight | Winner – Husqvarna.

Weight can cause fatigue with cut-off saws. The lightest saw was the Husqvarna weighing in at 30.8 lbs. Second lightest saw was the Hilti at 30.1 lbs, third went to Milwaukee at 33.35 followed by Makita at 34.25 lbs.

Note – the Husqvarna K770 gas saw has a weight of  26.12 lbs. without gas.

Best Concrete Cutter Battery Charging Time | Winner – Milwaukee and Hilti

In order to achieve gas saw performance you will need two sets of batteries. The theory is to have a battery(s) on the charger while you are working. This reduces downtime and maximizes your productivity. That being said, will the battery reach a full charge before you need it? The answer to that depends on how much cutting you are doing at one time.

The fastest battery charging time was a tie between Hilti and Milwaukee MX battery, both with charging times of 45 minutes. Its important to note that the Hilti ran off of two B22-255 batteries and to achieve this time you will need two chargers. Otherwise you’ll have to double this time.

Husqvarna was third with a 55 minute time, thanks to its “express charge” feature on the charger. This feature allows the user to press a button on the front of the charger to activate. However, you don’t want to fast charge batteries on a regular basis because it’s hard on the cells. A standard charge time is about 75 minutes. The express charge is there for when you need it. We are based in the North East USA and our electrical system is based on a 110V AC standard.  Its important to note for European customers that the Husqvarna charger is able to perform slightly faster on the 220V AC standard and give a 45 minute express charge.

The Makita dual charger simultaneously charges both Makita 40V 8.0Ah batteries at the same time in 76 minutes.

Best Priced Power Cutter | Winner – Hilti

These four saws are unquestionably pricey tools. In order for these saws to achieve gas performance you will need two sets of batteries. Replacement blades on these machines runs approximately $150.

The Milwaukee and Makita saws are offered in a kit that includes two sets of batteries and a charger. The Milwaukee comes with two batteries, whereas the Makita comes with four (the saw requires two batteries to function).

Our conclusion is that these cut-off saws all require two batteries to match one tank of gas. For pricing we included the saw, two sets of batteries, and a charger for the Husqvarna and Hilti.

The winner of the best price is the Hilti DHS 700-22 priced in our kit form at $2,493.00

• Tool cost: $1,183.00
• 4 batteries:  $243.00 each
• 2 chargers: $169.00 each

Second place was the Makita Power Cutter Kit totaling $2,699.00 and third was Milwaukee, sold as a kit for $2,999.00.

The most expensive cut off saw was the Husqvarna which when added all together was $3,996.00. This extremely high price is due to the cost of the batteries. The B750X battery is $939.00 each and when adding in two of them it contributes 50% of the total price. At this cost users could almost purchase two competitor saws for the price of the Husqvarna.

Overall Best 14″ Cordless Cut-Off Saw (Concrete Cutter) | Winner – Husqvarna

Its important to note that ALL of these cut-off saws performed well and were extremely close. Two of the manufacturers Hilti and Makita also have huge power tool platforms that their batteries will interchange with.  The other two Husqvarna and Milwaukee, only have a few dozen tools currently that their batteries will power.

The overall Best Cordless Cut-Off Saw in our testing was the Husqvarna with a score of 21.  Hilti came in second with 23 and Milwaukee just one point behind with 24.

Note: Given the number of categories scored for our overall ranking we decided to double the value of our performance tests.  Both the Concrete Endurance and Rebar Speed scores were multiplied by a factor of 2 in the final chart.  We feel that the cutting endurance and cutting power of these tools carry the most weight and importance to the potential end user.

The Hilti saw is technically a 12″ power cutter, had the shallowest depth of cut, but clearly punched above its weight in this test with a great feature set, low weight, and impressive run-time and speed scores.

The Husqvarna K1 Pace power cutter was a team favorite and a clear winner with top scores in five out of nine categories. It is a lightweight, well balanced cut off saw with great runtime, functionality and line of sight.

The Makita saw was heavy and powerful. It was the only saw we NEVER had to let up on and you can actually lean into cuts with. It has excellent features and ergonomics, a generous depth of cut and was second fastest in our metal cutting test.

The Milwaukee MX saw is a Gen 2 saw and was a speed demon when cutting metal averaging almost 3-seconds faster than the next concrete cutter. It too was a powerful cutter with an excellent depth of cut, great price with good features and ergonomics. The water connection issue hurt the MX saw and kept it from standing alone in 2nd place.

Best Value Cordless Concrete Cutter | Winner – Hilti and Milwaukee

Best value is typically awarded to the saw that performed well and is lowest or low in price. The Hilti and Milwaukee were close in scores and $500 apart in cost. With regard to performance the Milwaukee power cutter performed slightly better than the Hilti. One tool did well in concrete endurance, and the other in cutting speed.

The Hilti cordless cut-off saw surprised us all in its performance and frankly price. Hilti has historically been at the top of the pricing charts in all of our head-2-Head tests. The bottom line is both concrete cutters have great feature set, good ergonomics, and excellent charging times which is important to keep you in the “cutting” game.

Either of these cutters are great! ~ Rob

Closing Thoughts

The biggest issue with cordless cut-off saws is charge time. It’s our opinion that contractors who cut concrete with 2 tanks of gas or less a day are in the “sweet-spot” to convert to a battery power cutter.  If you are cutting all day and using 5 to 7 tanks of gas you should stay with a gas cutter or invest in more batteries.

Speaking of batteries, the Hilti and Makita tools both use batteries that are compatible with a wide variety of smaller tools (Hilti’s Neuron line and Makita’s 40v XGT line). This could be a factor in purchasing decisions.

Lastly, charge time, and power to charge is a consideration.  Many of these batteries require 45 minutes to charge, and  you also need to consider how remote you are working. Do you have access to electricity or an inverter to charge your batteries?

We get lots of comments about how we make the final rankings. There are dozens of ways to compare tools, our goal when testing is to achieve repeatable, consistent results. We share ALL the data from our tests, so you can re-rank the tools however you want. If you don’t care about an item we ranked? No problem. Remove that from the matrix above and re-rank them.

Hopefully you’ll find this Head-To-Head useful when considering purchasing a larger cordless power cutter, or comparing them to gas models.

Please take some time and check out our other head-to-Head tests at ToolBoxBuzz.com.

Thanks, “the TBBCrew.”

Best Cordless 14″ Cut-Off Saw (Concrete Cutter) | Video Review

Best Cordless 14″ Cut-Off Saw (Concrete Cutter) | Head-To-Head is a post from Tool Box Buzz

Best Battery-Powered Top Handle Chainsaw Testing

This Head-2-Head will take a look at the best battery top-handle chainsaw for 2023.  Battery technology has evolved to become arguably the king of outdoor power equipment. But does it measure up to what dedicated Pros need? In 2020 the ToolBoxBuzz crew hosted our first Best Cordless Chainsaw Head-2-Head where we evaluated twelve traditional rear handle saws. During that testing it was clear that a battery saw was an excellent option for a homeowner or DIYer, but not for full-time use in the forestry and tree care industry.

Fast forward to 2023 and the battery tool industry has continued to evolve. Additionally, the pro arborist and landscaping trades have seen an increased demand for pro-grade battery offerings. Many communities and even some states, like California, are moving to ban gas-powered OPE altogether. Bearing all this in mind, the TBB Crew set out to find out who makes the best battery top-handle chainsaw.

Top-handle chainsaws are often commonly referred to as climbing saws or bucket saws. They are designed for in-tree use by trained climbers or when working from a bucket truck in the air. These environments require the user to make cuts at adverse angles or from overhead or unsupported positions. They are often hung from the belt harnesses worn by arborists when climbing trees for takedown work. These unique demands require a saw to be compact and robust and move the handle location to the top of the saw to scale down the overall length.

Pro User Feedback

Scott Angelovic of Angelovic Tree Service, LLC.

Pro-user feedback is something we pride ourselves on at ToolBoxBuzz. In order to ensure that our testing protocols catered to tree care pros, we enlisted some local help. Our tests were conducted in Oxford, Connecticut by crew member Wes Bartosik. Additionally, Wes reached out to his friend Scott Angelovic of Angelovic Tree Sevice LLC. Scott is a long-time friend of Wes and a local business owner. Scott provided invaluable feedback on how each of our saws stacked up for pro use.

Jake Pollak better known as @DudeRanchDIY

ToolBoxBuzz was also fortunate enough to work with Jake Pollak of @DudeRanchDIY  for the first time on this project. Jake is an arborist by trade but also sells firewood and operates his own Youtube channel showcasing his firewood operation and equipment as well as arborist and chainsaw-related content. Jake is another Connecticut native and was able to provide us with some excellent feedback on the saws. Check out Jake’s YouTube, Facebook, and Instagram accounts where he cross-posted a lot of the content we worked on together.

Testing Criteria

In order to keep the sample pool as consistent as possible, we developed a set of selection criteria. First and foremost, the saw must be a purpose-built arborist saw designed for professional tree work. There are several saws on the market that happen to have a handle on top but are not tailored to professionals in any other way. Next, we limited the bar length to between 12″and 14″. Some models that were sent by manufacturers had their OEM bars swapped out to the proper length for testing. While we could not narrow down the pitch or gauge any further amongst samples, the bar lengths were kept consistent. Finally, we limited the battery pack Ah size to the kitted offerings from each manufacturer. Some of our manufacturers offer their saws as an a la carte system with multiple chargers and battery offerings (such as Husqvarna and Stihl). For these manufacturers, we selected the recommended battery offering for the tool.

The above-mentioned criteria provided us with a sample size of eight saws from six manufacturers. Makita and Stihl both had two models included in the testing. Makita with their legacy 36V 18V LXT X2 saw as well as the new 40V Max XGT and Stihl with their legacy pruning saw as well as their newest offering.

Saw Lineup

Echo

• Model: DCS-2500T
• Bare Tool Weight: 3.84 Lbs.
• Battery Platform: 56V eFORCE
• Battery Tested: 2.5 Ah
• Manual Adjustable Oiler
• Bar Length: 12″
• Chain Pitch: 3/8″ Low Profile
• Chain Gauge:  0.050″
• Tool Warranty: 5 Year Consumer / 2 Year Commercial
• Battery Warranty: 2 Year Consumer / 2 Year Commercial

Greenworks Commercial

• Model: 48TH12
• Bare Tool Weight: 6.10 Lbs.
• Battery Platform: 48V DualVolt
• Battery Tested: 4.0 Ah
• Automatic Oiler
• Bar Length: 12″
• Chain Pitch: 3/8″
• Chain Gauge: 0.050″
• Tool Warranty: 2 Year Limited
• Battery Warranty: 2 Year Limited

Husqvarna

• Model: T540i XP
• Bare Tool Weight: 5.66 Lbs.
• Battery Platform: 40V
• Battery Tested: Bi200X 5.2 Ah
• Manual Adjustable Oiler
• Bar Length: 12″, 14″,16″
• Chain Pitch: 0.325″ Mini
• Chain Gauge: 0.043″
• Tool Warranty: 3 Year Consumer / 2 Year Commercial
• Battery Warranty: 3 Year Consumer / 2 Year Commercial

Makita 36V LXT

• Model: XCU08
• Bare Tool Weight: 6.28 Lbs.
• Battery Platform: (2x) 18V LXT
• Battery Tested: (2X) 5.0 Ah
• Manual Adjustable Oiler
• Bar Length: 14″, 16″
• Chain Pitch: 3/8″ Low Profile
• Chain Gauge: 0.043″
• Tool Warranty: 3 Year Limited
• Battery Warranty: 3 Year Limited

Makita 40V XGT

• Model: GCU03Z
• Bare Tool Weight: 5.74 Lbs.
• Battery Platform: 40V Max XGT
• Battery Tested: 4.0 Ah
• Manual Adjustable Oiler
• Bar Length: 12″, 14″, 16″
• Chain Pitch: 3/8″ Low Profile
• Chain Gauge: 0.043″
• Tool Warranty: 3 Year Limited
• Battery Warranty: 3 Year Limited

Milwaukee M18 FUEL

• Model: 2826-22T
• Bare Tool Weight: 7.30 Lbs.
• Battery Platform: M18 FUEL
• Battery Tested: 8.0 Ah
• Manual Adjustable Oiler
• Bar Length: 12″, 14″
• Chain Pitch: 3/8″ Low Profile
• Chain Gauge: 0.043″
• Tool Warranty: 5 Year Limited
• Battery Warranty: 3 Year Limited

Stihl MSA 161T

• Model: MSA 161T
• Bare Tool Weight: 4.86 Lbs.
• Battery Platform: 36V AP Series
• Battery Tested: AP 300S 7.2 Ah
• Manual Adjustable Oiler
• Bar Length: 12″
• Chain Pitch: 1/4″ PICCO Micro 3
• Chain Gauge: 0.043″
• Tool Warranty: 3 Year Consumer / 2 Year Commercial
• Battery Warranty: 3 Year Consumer / 2 Year Commercial

Stihl MSA 220TC-O

• Model: MSA 220TC-O
• Bare Tool Weight: 6.10 Lbs.
• Battery Platform: 36V AP Series
• Battery Tested: AP 500S 9.4 Ah
• Manual Adjustable Oiler
• Bar Length: 14″
• Chain Pitch: 3/8″ PICCO
• Chain Gauge: 0.050″
• Tool Warranty: 2 Year Commercial Only
• Battery Warranty: 3 Year Consumer / 2 Year Commercial

Testing Criteria

Our saws were evaluated and ranked based on the following categories;

• Ability to Stall Out
• Small Diameter Speed Cut Testing
• Large Diameter Speed Cut Testing
• Weight
• Decibel Output
• Price
• Features
• Ergonomics

Based upon this information we named a best overall winner as well as a best value winner.

Safety Considerations

Chainsaws are an inherently dangerous tool by design. According to the US Consumer Product Safety Commission, there were 28,859 chainsaw-related accidents in 2020. The majority of those accidents (11,630) were to users’ legs. Bearing this in mind proper safety gear was mandatory for our testing crew. Each test cutter was required to wear safety toe boots, leg protection, as well as eye protection.

The ToolBoxBuzz crew strongly recommends any user interested in purchasing or working with a chainsaw invest in some quality protective gear. It is a simple initial investment that can save your life.

Ability to Stall Out

Before beginning our performance testing, we wanted to measure the ability of the user to stall out the saw during a cut. Traditionally a pro-grade gas saw can be “leaned into” when cutting to push through tough material, pinching forces of the wood,  or overcome a slightly dull chain. Battery-powered saws are far more temperamental and less forgiving of the user levering them during use. Many manufacturers include overload protections in their battery tools to shut the saw down if the motor or the battery is being overworked. While this is a great idea in theory to protect the tool, it can be problematic for pros in the field.

An arborist may be suspended in the air making an intricate hinge cut on a limb. At that moment, the user needs the saw to be able to power through and not bog down or stall out completely and need to be reset. Based upon this we set up a testing rig using a section of maple log. The test cutter was then instructed to make a crosscut while burying the saw to the nose and leaning into the cut. The test cutter was also instructed to apply the same amount of force each time in order to cause the saws to stall out.

The Two best performers in this test were the Milwaukee and the Stihl MSA220TC. Our test cutter described both as “Beastly” and was unable to stall them out in the test log. Both saws provided outstanding consistent power throughout the cut. In second place was the Greenworks saw, which slowed during the test but continued cutting while being pushed through the cut. All three of these saws demonstrated an excellent low-end torque band that is ideal for demanding cutting tasks.

The Husqvarna and smaller Stihl MSA161T were our next best performers, stalling out only once the bar was at a depth consistent with the full width of the bar. Both Makita saws stalled out once the saw bar reached approximately half the width of the bar into the cut. Once this occurred, both saws had to be lifted up and then re-engaged to begin cutting again. The Makita XGT then stalled a second time before completing the cut. It seemed to our test crew that the Makitas were stalling in order to preserve the electronics, but this additional stop/start represents wasted time and productivity for professional users.

The Echo struggled the most in this test. The saw stopped multiple times and struggled to perform when being leaned on by our cutter. The Echo is also the smallest saw we tested and appears to be ideally suited for cutting smaller-diameter limbs or pruning work. Our test crew all agreed that the saws with larger full-size chains were preferable for commercial work and that reset buttons belong in video games and not on chainsaws.

Speed Cut Testing

In order to determine our fastest cutter amongst the sample group, we designed two speed-cutting tests. The first was a smaller diameter cut to simulate a limbing or pruning job and the second was a larger diameter cut to simulate a full takedown job. For both tests, we used a green hardwood log from a tree species native to New England. We focused on green wood with this H2H in order to simulate the conditions that pros would encounter in the field. To keep it as green as possible, we dropped some trees on the day of testing!

Scott using a Stihl MS400 to drop our test log tree.

Both tests were performed on sugar maple logs. Maple was selected as a medium-grade hardwood to offer a compromise between some harder species like oak which is plentiful in the Northeast and some of the pine species that are common on the West Coast. The Janka scale, which is the industry standard for hardness, lists sugar maple at approximately 1,450 Lb./Ft. The smaller diameter piece had an average measured diameter of 4.87″ and the larger diameter piece averaged at 7.75″.

Moving our test log into position with a Vermeer mini-skid machine with a hydraulic grapple.

The test cut pieces were strapped securely to a log stand and the same test cutter performed the cuts with all eight saws. The instructions for the crew member were to guide the saw through the cut without leaning into it and allow gravity and the weight of the saw to do the work. For the smaller diameter test (T1), the cutter performed a down, up, and down cut to make a total of three cookies. The larger diameter test (T2) was limited to a down and up only in order to prevent stall out or thermal overload. This was the first test performed; all eight saws had fresh factory sharp chains.

Small Diameter Speed Cut T1

The winner of T1 was the Stihl MSA220 at 8.47 seconds, finishing almost three seconds faster than the runner-up. Milwaukee came in second at 11.10 seconds and Husqvarna in third at 11.56 seconds. The slowest cutter for T1 was the Echo at 23.35 seconds.

Larger Diameter Speed Cut T2

The Makita XGT saw powering through our larger diameter speed cut test.

The winner of T2 was the Stihl MSA 220 at 10.97 seconds. T2 showed the Makita XGT rising to second place at 11.59 seconds and Husqvarna beating out Milwaukee for the number three spot by 0.01 seconds. The slowest cutter for T2 was the Echo again at 39.29 seconds.

The Stihl was absolutely unstoppable. The saw’s heavier weight and powerful battery system allowed the saw to rip through both tests. This test also demonstrated the capabilities of the new Makita XGT platform compared to the legacy Makita 36V saw. The XGT platform provided constant speed and power throughout the trial.

The Echo was the smallest saw we tested and lagged behind in both tests by a substantial margin.

Weight

Weight is a huge factor to consider when selecting a top-handle saw. By design, these tools are meant to be used at adverse angles and uncomfortable positions. A tree care pro may use one of these saws at shoulder height or above for hours at a time. Therefore in order to paint the complete picture of what each of these saws weighs, we took two measurements.

The first was the bare power-head weight. We weighed each saw with an empty bar oil reservoir and removed the bar and battery. Then we attached the bar and chain, filled the oil reservoir, and inserted a battery. We ranked the tools based on the fully assembled weight but thought that the bare powerhead weight and subsequent increase in weight was a good data point to collect.

The lightest assembled saw was the Echo at 7.46 Lbs. Second place went to the Stihl MSA161T at 9.84 Lbs. and third place to Husqvarna at 10.16 Lbs. The heaviest assembled saw was the Stihl MSA220TC at 12.38 Lbs.

The Echo is an incredibly light saw in the hand at under four pounds as a powerhead. Even fully assembled the Echo is almost as light as the Milwaukee powerhead. On the opposite end of the spectrum, the Stihl MSA2210TC powerhead is about one pound heavier than its gas counterpart the MS201T.

Decibel Output

The level of received noise at the ear is a concern for the longevity of all professionals. According to OSHA standards, any exposure for eight hours of 85 decibels or higher requires hearing protection. In order to measure the noise output of each saw, we placed them on a jig with a decibel meter placed in a designated location to measure noise output. We then ran each saw for ten seconds at full speed, while not under load, and recorded the decibel range.

The quietest saw was the Stihl MSA161T at 80.8 decibels. This was the only saw that was under the 85-decibel threshold as well. Second place was Milwaukee at 91.3 decibels and third place went to Husqvarna at 92.4 decibels. The loudest saw tested was the Makita XGT at 100.9 decibels.

An interesting field note from our pro-user testers was that decibel ratings were really not a concern to them. They all wear helmets with built-in hearing protection and radio capabilities for communicating with their ground guys. However, the lower decibel output of all of our battery saws, compared to their gas counterparts, can be beneficial when working in areas with noise-based work hour restrictions, such as residential neighborhoods.

Price

For this H2H we chose to rank the tools based on a kit price. While carpenters, plumbers, and electricians, are likely loyal to a battery platform and heavily invested, the same cannot be said of most tree care pros. A tree care pro is likely buying a battery top handle saw for the first time and has no other tool that runs on that platform. Therefore we chose to select a kit option for the price ranking that includes the battery we used during testing.

The winner of the price rankings is a tie between Greenworks Commercial and Milwaukee. As of July of 2023, both companies are offering a kit with battery and charger for $499.99. In second place is Echo at $549.99 and third place is the Makita 36V at $579.00. Our most expensive saws are the Husqvarna at $1,049.00 and Stihl MSA220TC at $1,169.97 as kits.

While price is important to all users, we chose to not include it when determining our final rankings.

Features

Our entire saw lineup featured outstanding professional-grade features. For instance, all eight saws included manual chain tension adjustment systems. This traditional, tooled, style of adjustment is our preferred method due to its robustness. In order to determine which saw had the best set of features, we outlined nine total evaluation criteria. We then ranked each saw’s feature on a scale of one to three, with three being the best. The saw’s total overall score was used to determine rank. Our evaluation criteria are as follows;

1. Felling Spikes
2. Chain Brake Contour/Response
3. Lanyard Ring(s)
4. Electronic Chain Brake
5. Automatic Oiler
6. Manual Chain Tensioner
7. Additional Modes
8. Standout Features
9. Safety Auto Shut-Off

The saw with the best features is the Milwaukee. The M18 saw has outstanding aggressive felling spikes as well as a large manual chain brake lever that is responsive and has a very positive click action. The steel lanyard ring is in a great position and locks in the open position. It has a very responsive electric chain brake and the chain tensioner features an extra bar stud to lock the mechanism in securely. Our crew agreed that an automatic oiler system is their preferred option, but Milwaukee’s manual adjusting oiler performed well in the highest output setting. The Milwaukee is also the only saw with an onboard saw wrench or “scrench”. While not an absolutely mandatory feature, it is a nice bonus.

Second place went to the Stihl MSA22oTC-O, which has an outstanding billet of professional-grade features. In fact, the “O” designation in the Stihl’s name refers to their electronic bar oil monitoring system. The saw will monitor the flow of bar oil via an internal laser. The system also monitors for dirt and contaminants. When the oil is low or full of debris, a light will activate on the saw’s main control panel to alert the user. This feature was unlike anything our testing crew had seen before.

Where Milwaukee excelled over the Stihl to our crew was with the different safety auto shut-off systems. The Stihl has a push-button activation switch to turn the saw on and off. There is also a warning light to alert the user when the chain brake is turned off as well as a tang safety in the top of the grip that must be depressed. Once the user releases that tang safety, with the chain brake off, the saw shuts off in about five seconds. This was a real annoyance to our crew during testing and our pro users agreed that this was too fast. Conversely, the Milwaukee uses a spring-loaded tang safety in the grip with no additional on/off switches. It is intuitive to use and ruggedly simple. Our pro-user crew agreed that Milwaukee’s system would be more user-friendly and productive for them.

Third place resulted in a tie between the Echo and Husqvarna saws. The Echo is an extremely lean-built saw and doesn’t have many extra bells and whistles. It lost points due to the shorter felling spikes but has a simple and excellent push-button activation switch. The Husqvarna features an excellent digital battery display at the activation switch to show power consumption in real time as well as an Eco mode for battery conservation. However, the Husqvarna chain tensioning mechanism makes it difficult to get seated properly when removing the clutch cover and changing bars and chains. Twice the Husqvarna saw chain completely slacked out during our test cutting. We experienced the same issues in our 2020 Head-2-Head testing.

Rounding out the category, the Makita 36V saw has an impressive feature set, including a high-performance “Turbo” cutting mode. But the mode is difficult to switch back and forth from. The Makita XGT lacks some of the additional features of the legacy 36V saw, but both offerings have excellent felling spikes and chain brake designs. The Greenworks Commercial and Stihl MSA-161T had very basic features compared to the rest of the test sample. The Greenworks saw lost points due to having rounded felling spikes that did not grab into our cutting materials during testing as well as a confusing power activation button.

Ergonomics

Ergonomics is one of our most subjective categories, but is one of our favorite and most discussed evaluations. If a tool is not comfortable or works against the user in any way, it is almost worthless. Similar to our Features section, we chose a total of six evaluation criteria to rank our battery top-handle chainsaws. The ergonomics of a top-handle saw are critical to a pro user in the field when working in the air, wearing gloves, or working in inclement weather. That is why we selected the following categories for evaluation;

1. Grip Comfort
2. Grip Contour
3. Forward Handlebar Angle
4. Bar Oil Fillcaps
5. Weight and Balance
6. Ease of Battery Change

The winner of this section is a three-way tie between Echo, Makita XGT, and the Stihl MSA-220TC. All three saws featured well-contoured and comfortable grips. The texture on all of them is excellent and all of the controls are easy to reach with one hand. The forward handlebars are also out of the way but easy to reach with an off-hand. Weight and balance were interesting with these models because they represent the best of our small, medium, and large offerings. The Echo is lighter and more compact, but both the Makita XGT and Stihl are compact in their overall design with no wasted space.

Although all three saws received the same overall score, the Echo had the best and most comfortable grip of the three as well as the nicest bar oil reservoir caps. However, the Makita XGT and Stihl have superior battery-changing mechanisms. The Stihl is the easiest to change batteries thanks to the battery being spring-loaded and inserted from the top of the saw.

Husqvarna took second place in ergonomics for battery top-handle chainsaws with excellent weight and balance as well as very comfortable grip material and handlebar angles. The criticisms of the Husqvarna were that the chain brake lever is too close and can be cramped on the user’s hands. Additionally, the sliding tang safety on the top of the grip was awkward to all of our test cutters. The Milwaukee came in third place with excellent grip materials as well as the most room for your hands of all of the saws test. The Milwaukee is a very big saw though. It sacrificed compact size for more room and feels bulky compared to most of the other saws. The side handlebar of the Milwaukee also bows out further than any other saw and gives it a Beachcomber bicycle feel.

Finally the Makita 36V saw was bulky and more off-balance than its counterparts due to the two-battery system. While they are easy to change, managing two batteries was not something our test crew viewed as desirable. The triple manual grip safeties of the Stihl MSA-161T were our least favorite and seemed almost impossible to use, safely, for lefties. The Greenworks saw felt off-balance and the controls were cramped and on top of each other.

Best Value Battery Top-Handle Chainsaw

One of our favorite categories to name is the Best Value, especially when we are talking about a battery top-handle chainsaw. These are expensive tools and present pro-users with a large financial investment. So which saw gives the best performance while still remaining reasonably priced? It is hands down the Milwaukee M18 Fuel.

The Milwaukee battery top-handle chainsaw finished in the top three of every category except for weight. Additionally, it achieved a first-place finish in the features category while tying for first place in the Stall Out test. Furthermore, Milwaukee also tied the Greenworks saw as our most affordable saw tested.

Overall Best Battery Top-Handle Chainsaw

At the completion of our testing, all of the data we gathered on the saws was compiled. When then used this to create rank structures for every category and finally used those ranks to create an overall final rank structure. The saw with the lowest number of points in this final ranking structure was our overall winner.

With a final overall score of nineteen points, our best battery top-handle chainsaw is the Milwaukee M18 Fuel. The Milwaukee is ergonomic and powerful with well-thought-out features. The safety system on the M18 saw was also one of the most preferred designs by our test crew due to its simplicity and similarity to their traditional gas-powered saws. The Milwaukee is a large saw though and is heavy. Because of that, our pro users weren’t sure if it would be suitable for full-time climbing work. The fact that the Milwaukee battery platform is so widespread and commercially available is a nice bonus but was not a determining factor for our tree care pros.

Second place was a tie between the Stihl MSA-22TCO and the Husqvarna. The two biggest names in the chainsaw world and both companies make an incredible battery-powered top-handle chainsaw. The Husqvarna has been on the market for several years now and has remained mostly unchanged. After testing it we realized that this is because Husqvarna got it right with the first generation. It is a fast, light, powerful, and nimble saw. The Stihl is brand new to the market and focuses more on raw power. We described the saw as “Beastly” earlier and that really is the best word for it. The Stihl is hands-down our top choice for demanding take-down work. Our test crew all greed that the Husqvarna and Stihl would be their top choices as tree care professionals and likely the only choices that would earn a coveted spot in their tree trucks due to the commercial warranties, dealer support networks, and overall reputation of both brands in the industry.

Third place went to the Stihl MSA-161T which shares many of the same perks as its younger, but bigger, brother. However, the MSA-161T has a proprietary bar design and uncommon chain size that make it less desirable. Stihl also does not do online sales, even for parts, making it more difficult to source these bars and chains.

All smiles!

The Makita XGT took fourth place overall. Showing that it is a product-improved version of the legacy Makita 36V saw. The improved battery technology and electronics of the XGT platform make for a saw that is really enjoyable to cut with. The legacy Makita and Echo tied for fifth place. The Echo struggled in our performance cutting tests but was a crew favorite thanks to its lightweight, great ergonomics, and professional-grade features. For smaller-diameter cutting tasks, the Echo is definitely worth a look. The Greenworks Commercial came in sixth place overall. While powerful, our crew agreed that it lacked some of the features and ergonomics they want in a saw.

Final Thoughts

Overall our test crew was impressed by the evolution and capabilities of all of the battery top-handle chainsaws tested. The saws discussed above are true professional-grade tools and are capable of performing a variety of tasks common with the Arborist and tree care industries. We would strongly encourage any user out there considering a battery-powered option to give it a chance. The ease of battery-powered electric motors versus traditional gas-powered engines is well discussed and documented. They make for an exceptional user experience and will only get better with time.

If you are interested in purchasing any of the saws mentioned in this article, please check out our Buy Now links listed below. These links will bring you to some of our preferred industry partners such as ACME Tools. Additionally, you can find Echo, Husqvarna, and Stihl battery-powered OPE at your local outdoor power equipment dealerships.

Best Battery Top Handle Chainsaw Head-To-Head Video

Best Top Handle Chainsaw | Head-to-Head | 2023 is a post from Tool Box Buzz

Best Cordless Blower | Head-To-Head

What would the perfect cordless leaf blower be? Wait…can we even call them leaf blowers? I certainly don’t use mine for leaves, I use them to blow sawdust on my job sites, my tools, out of my van and tool shed, or to clean off my patio and porch. They’re just blowers!

Comparing 15 Blowers

Fifteen manufacturers sent us their best handheld cordless blower. The majority of these blowers can be found in kit configuration and are sold at most common and online retailers. In past testings, we’ve received comments that we should include Harbor freight tools, so in this head-to-head test, we’re happy to welcome Harbor Freight’s Atlas blower to this test.

ATLAS

Model – 56994
Voltage – 80V
Battery Watt Hour – 288 Wh
Max Air Speed (MPH) – 150
CFM’s – 605 CFM’s
Length – 35-⅜”
Weight – 4lbs, 6oz
Price – 274.99 (when added kit components)

CRAFTSMAN

Model – CMCBL730P1
Voltage – 20V
Battery Watt Hour – 100 Wh
Max Air Speed (MPH) – 110
CFM’s – 410 CFM’s
Length – 33-½”
Weight – 5lbs, 7oz
Price – $149.00

DEWALT

Model – DCBL772X1
Voltage – 60V
Battery Watt Hour – 180 Wh
Max Air Speed (MPH) – 125
CFM’s – 600 CFM
Length – 36-¾”
Weight – 6lbs, 2oz
Price – $299.00

ECHO

Model – DPB-2500
Voltage – 56V
Battery Watt Hour – 252 Wh
Max Air Speed (MPH) – 158
CFM’s – 549 CFM’s
Length – 36-¼”
Weight – 5lbs, 6oz
Price – $199.99

EGO

Model – LB7654
Voltage 56V
Battery Watt Hour – 280 Wh
Max Air Speed (MPH) – 200
CFM’s – 765 CFM’s
Length – 36-½
Weight – 4lbs, 11oz
Price – $329.00

GREENWORKS

Model – BLB489
Voltage: 80V
Battery Watt Hour – 180 Wh
Max Air Speed (MPH) – 170
CFM’s – 730 CFM’s
Length – 37-1/8
Weight – 5lbs, 8ozs
Price – $342.99

HART

Model – HLB07VNM
Voltage: 40V
Battery Watt Hour – 180 Wh
Max Air Speed (MPH) – 155
CFM’s – 600 CFMs
Length – 37-⅜”
Weight – 6lbs, 12ozs
Price – $138.00

KOBALT

Model – KLB 1040A-03
Voltage 40V
Battery Watt Hour – 160 Wh
Max Air Speed (MPH) – 120
CFM’s – 520 CFM’s
Length -33-¾”
Weight – 5lbs, 4ozs
Price – $169.00

MAKITA

Model – GBU01M1
Voltage 40V
Battery Watt Hour – 160 Wh
Max Air Speed (MPH) – 143
CFM’s – 565 CFM’s
Length – 33-1/2″, 35-1/2″, 37-1/2″ (ADJUSTABLE)
Weight – 5lbs, 5ozs
Price – $439.00

MILWAUKEE

Model – 2824-20
Voltage 18V
Battery Combined Watt Hour – 288 Wh
Max Air Speed (MPH) – 145
CFM’s – 600 CFM
Length – 37-⅜”
Weight – 6lbs, 1oz
Price – $707.00 (not kit)

RIDGID

Model – R01601K
Voltage – 18V
Max Air Speed (MPH) – 130
Battery Watt Hour – 288 Wh
CFM’s – 510 CFM’s
Noise dB – 83.1
Length – 34-¼”
Weight – 5lbs, 7ozs
Price – $241.53

RYOBI

Model – RY404100
Voltage – 40V
Max Air Speed (MPH) – 190
CFM’s – 730 CFM’s
*Battery Watt Hour – 144 Wh
Noise dB – 84.6
Length – 37-⅞”
Weight – 6lbs, 4ozs
Price – $269.00
*Wh based on one battery

SKIL

Model – BL4713-c-11
Voltage 40V
Battery Watt Hour – 100 Wh
Max Air Speed (MPH) – 193
CFM’s – 500 CFM’s
Length – 36”
Weight – 4lbs, 3ozs
Price – $159.00

STIHL

Model – BGA 86
Voltage: 36V
Max Air Speed (MPH) – 154
Battery Watt Hour – 337 Wh
CFM’s – 459 CFMs
Length – 38-½” (ADJUSTABLE)
Weight – 6lbs, 5ozs
Price – $839.97 (not kit)

TORO

Model – 51822
Voltage – 60v
Battery Watt Hour – 216 Wh
Max Air Speed (MPH) – 157
CFM’s – 605 CFMs
Length – 37-½”
Weight – 5lbs, 8oz
Price – $290.03

Cordless Blower Testing | 7 Criteria

Our goal was NOT to verify marketing claims, instead, we used ANSI testing standards as a guide, to create consistent, repeatable, and measurable data that you can make intelligent decisions on.

Our team scored the blowers on seven criteria, each ranked independently, and the “Overall Best Cordless Blower” was determined using the combined test results.

We include but did not rank price and best value categories, but list them here for your own informational purposes.

7 Scoring Criteria

1. Pitot Tube Run-time Testing – Directly measure air speed with a pitot tube and calculate MPH and CFM during a runtime performance test
2. Weighted Sled Test – tested the thrust performance with a sled rig on rails.
3. Ergonomics and Features – Ergonomics is really important to users and an important category to consider when purchasing any power tool.
4. Balance – Measured the balance and resulting rotation in the off and full throttle states.
5. Noise -Measured Decibels at full throttle
6. Best Value – Not ranked.
7. Price – The kit price at the time of publishing. Not ranked.

Anemometer | Pitot Tube Air Test

I’ll be honest, I had to ask Jeff what a Pitot tube was. 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.

Using fluid dynamics theory and measured environmental parameters like temperature, pressure, and humidity, the average and peak MPH and CFM values can be calculated.

We replicated this ANSI procedure to validate the measured MPH values gathered from our pitot tube instrument. Both measurements aligned. Here’s a summary of that procedure:

1. We used a 13.8 in ± aluminum plate as a force plate for our electronic scale.
2. We vertically mounted and centered the blowers in our rig and off the force plate 5”.
3. The blower was operated for 10 seconds, and the result was recorded.
4. Three tests were performed for an average measurement.
5. Barometric pressure, temperature, and humidity were recorded
6. Used ANSI blower performance equations to calculate theoretical peak and average blower speed

Anemometer and Pitot Tube | Testing

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 full throttle. The data was collected at 1 Hz sample rate or once per second until the battery was drained.

An ExTech HD350 Pitot Tube Anemometer was used to perform this test. The chart below shows data for all 15 blowers.

Using this data we were able to determine and calculate 4 important metrics for each blower, ranked them separately, and also combined them for an “Airflow Performance” winner.

1. Run-time in minutes
2. Average Speed
3. Average CFM
4. Total air moved

Run-time | Sustained Performance Winner | Stihl

You can see from the chart that the Stihl ran the longest, at 25.4 minutes. Second place was ECHO with 19.4 minutes, followed in third place by Milwaukee at 16.7 minutes.

This is a good time to talk about open and closed-loop battery control and how it relates to sustained performance. One of the biggest complaints with cordless blowers is their poor run-time and tendency to suffer a drop in sustained performance over time, as the battery discharges.

Three blowers Makita, Milwaukee, and Stihl all have closed-loop control on the battery output enabling them to run at a consistent [not peak] speed, for the life of the battery. While these blower batteries may have more power that could be drawn from them, these closed loop controls limit the output so an expected level of sustained performance can be delivered over a longer period of time. This is a feature that appeals to Pro users.

In contrast, most of the blowers, we tested, showed open-loop control.  Their peak performance was delivered within the first few moments of battery discharge, and then a variable level of declining performance results, as the battery discharges.  For example, the Ryobi blower showed a 22% drop in performance when comparing a fully charged battery to one that is half “empty”.

The three closed-loop control blowers we tested, all handle the dwindling voltage of their batteries a bit differently:

• Makita ran at a consistent speed until it quit.
• Milwaukee ran at a consistent speed for over 90% of the battery life before rapidly fading.
• Stihl ran consistently for over 80% and then when the voltage began to drop, it forced a reduction to 75% peak power to continue on for an additional 5 minutes.

As pro tool users, we feel that having a blowers power stay consistent, and maintain its performance over the entire battery charge is really important.

Average Speed Winner | Stihl

Speed is measured in miles per hour and measures air velocity, or more specifically, the rate at which air passes through the blower’s nozzle.

A higher mph rating, results in the ability to push more dense or sticky debris like gravel or wet leaves. One interesting fact is that many tool companies market their blower’s performances by their PEAK measurement. We used average recordings to give you the MOST realistic and honest measurement.

The Stihl performed the best with an average speed of 124.5 mph. Second place was Milwaukee at 119.8 mph and closely followed in third place was Makita at 119.5 mph.

Note – The chart shows the EGO with the highest initial peak speed, but its average performance over time dropped, resulting in a fourth placement.

CFM Winner | EGO

Cubic feet per minute or CFM was calculated by taking the measured speed data and combining it with the area of the nozzle opening, to calculate the volume of air moved per minute.

The EGO came in first with 659 CFM. Second place was Makita with 643 CFM, and third was HART with 628 CFM.

The higher the CFM value, the more air your blower produces, resulting in a wider area cleaned in a shorter time.

Total Air Moved Winner | Stihl

The winner of this category is a combination of run-time and average CFM. This is an indication of the total amount of work performed on a battery charge.

The Stihl performed the best, coming in at 11,550 cubic feet, followed by ECHO with 11,126 cubic feet. Third place was Milwaukee with 10,032 cubic feet.

Overall Airflow Performance Winner | Milwaukee

It’s important to note that two of the above categories are power performance values, and the other two are indications of battery size and runtime. In order to level the playing field between tortoises and hares we combined all four categories to see how the blowers performed in totality.

The winner was Milwaukee, followed closely by EGO and Stihl.

Weighted Sled Test | Power Test Winner | EGO

Who doesn’t like a strong-man contest?  We’ve touched on the importance of MPH and CFM, but the importance of where these two values intersect is the overall “force or thrust” that a blower can produce.

Manufacturers measure this force in Newtons in their development and testing. We developed a test rig to indirectly measure thrust and provide a good visual understanding.

We built a weighted sled that rides on low-friction wheels attached to inclined rails.

Sled Procedure

Prior to each blower test the rails and wheels were cleaned and lubricated with silicone. To perform this test we placed each blower’s tube onto a v-shaped rest, mounted to the sled. We placed the blower body onto a tool rest setting the blower in the same plane as the sled rails. Once set, we ran each blower for a 10-second count and recorded the sled movement on a measuring tape mounted to the sled. Three tests were completed for an average measurement. All blowers were tested with a 5.5 weight placed on the sled rig.

Two blowers maxed this test out, they were the EGO and Ryobi. We then added a second 5.5. lb plate and retested both blowers. The Ryobi was able to move the sled approximately halfway, while the EGO maxed out the rig a second time!

The sled topped out at 70 inches. Our chart below does not account for the additional weighted tests for EGO or Ryobi. EGO was the clear winner, Ryobi was second followed by Harbor Freight’s Atlas blower which was able to move the sled 66 inches.

Blower Nozzle or No Nozzle | What’s Best?

We wanted to see the direct impact of the nozzles on our weighted sled rig. The nozzles are designed to narrow the opening of the chute and increase the speed of air coming out.

Many people don’t realize that manufacturers will often use a nozzle to measure higher peak MPH values and will use the wider chute opening without the nozzle to list their peak CFM number. The same blower, but tested with different configurations.

Most manufacturers supply a nozzle because many users feel it increases performance, and they ask for it. The reality is that adding a nozzle may increase the localized air stream speed, but the added friction and constriction reduce the overall performance.  [E.g Milwaukee reduces from 17.5 to 17 Newtons, but increases from 145 to 155 mph]

Our sled test results showed that adding a nozzle to the blower drastically reduced the blower’s performance on the sled test. For example, the Ryobi which was able to max out the test sled at 70-inches without a nozzle, was only able to achieve 58-inches with a nozzle. Similar results were observed with EGO and Milwaukee nozzles.

Ergonomics and Features Winner | EGO

This category is compiled from the combined opinions of the TBB crew after using the tools. Grip, throttle, battery removal, intake placement, and adjustable chute length were evaluated.

The EGO eked out a win with 10 points, followed closely by Makita and Milwaukee which tied for second place each with 11 points.

Grip

While all blowers had relatively comfortable grips, both the EGO and Milwaukee stood out. They have base stands that can double as a two-handed hold for overhead use or off-balance use.

Throttle | Trigger | Power On

When it came to evaluating the blower’s throttle, the TBB crew favored blowers with a single point of activation. Unfortunately, most blowers employ a boost button, which we feel is an unnecessary hassle and a marketing gimmick.  Some of the blowers, like the Craftsman, have boost features that can be locked on – we preferred that to having to hold the button down. Pro users definitely do not want to have to engage a second button.

The Milwaukee throttle stood out with ambidextrous use and had a very responsive throttle control and no boost button.

Lastly, some blowers have a power-on switch, or safety feature, in order to power on the trigger. Most of the crew found these features frustrating.

Battery Insertion and Removal

When considering the battery removal and installation, the crew really liked those blowers, like the Kobalt, that offer a spring-loaded ejection.

Milwaukee lost points in this category by being the only blower to employ dual batteries.

Adjustable Chutes

Makita, along with Stihl offers an adjustable chute, with several configurations. We felt this may appeal to users who might want to adjust their blower chute to their height.

Air Intake Location

Intakes were also evaluated. The team favored rear-mounted over side-mounted intakes due to side-mounted intakes sucking in the user’s pant legs when held close to the body.

Balance and Rotational Force Winner | ECHO

Too much rotational force can result in a blower that you’re constantly fighting to control, or worse results in a wrist injury like tendonitis. Wrist tendonitis is frequently caused by activities requiring sideways motion of the wrist while gripping. Activities such as using a blower in a side to side motion can lead to Dequervain’s tendonitis.

Rotational Force Rig

We built a rig to hold each blower’s handle to simulate a neutral grip position. The rig allowed the blower to rotate freely on this axis.

We used some image analysis to capture the angle of the blower chute relative to the horizon. The angle at rest with the blower powered off was measured, followed by the blower in the full throttle state.

We considered two values to be the most important when analyzing this data and used their individual rankings to determine the blower with the best balance.

1. Angle under load
2. Difference between no-load and full load

The first was the angle under load relative to the horizon. We found the most strain on the wrist was felt when the blower wanted to pitch down directly at the ground, forcing the user to pull the blower back up to a useful working angle.

The blowers we tested pitched down between a comfortable 40 degrees, to a very uncomfortable near vertical 89 degrees.

The second value we considered important was the change or Delta between the blower at rest and under load. A well-balanced blower should have minimal change in pitch when the throttle is activated. A bower that swings a large amount is likely to be harder to control. The smallest delta observed was 15 degrees and the highest was 57 degrees.

The ECHO took the best Balance category. The Echo had a no-load balance of 19 degrees and deflected to 40 degrees down under full throttle. This comfortable 40 degrees nose-down attitude coupled with the relatively small change of just 19 degrees scored it top marks.

Craftsman came in second with a  no-load measurement of 31 degrees and a full load of 46 degrees. Stihl followed in third place with 19 and 41 degrees.

Cordless Blower Noise Winner | Stihl

OSHA sets legal limits on noise exposure based on a worker’s 8-hour work day. For noise, OSHA’s permissible exposure limit is 90 dB.

To measure relative decibels mounted the blowers. back into our rotational rig, and mounted a decibel meter 24” away from the blower to simulate the distance between a user’s ear and wrist. Three readings were captured and an average was recorded.

The blower that was the quietest was the Stihl coming in at 81.5 dB. The second quietest was the RIDGID averaging 83.1 dB followed by the RYOBI averaging at 84.2 dB.

The blowers that were the loudest were the DEWALT and ECHO averaging 97.9 db.

Best Price Winner | Hart

When purchasing tools, price is unquestionably a crucial factor, particularly for those of you who are just beginning out in the trades or are DIY/Homeowners just starting out.

We ranked pricing as *kits and with blowers that weren’t sold in kit form, we included a battery(s) and charger to even the playing field.

* Ryobi kit comes with 2 batteries.

At the time of testing, the best-priced blower kit was the Hart coming in at $138.00. The second lowest price was the Craftsman at $149.00 and the third was the Skil at $159.00.

The most expensive blower we tested was the Stihl BGA 86, coming in at $839.97.  The majority of these blowers can be purchased at ACME Tool or your local big box store.

Best Value Blower Winner | Hart

Price and quality will continue to be the top deciding factors for consumers. In today’s economy, consumers are looking for ways to stretch their dollars further, and tool companies need a solution to deliver a well-made, powerful tool at a competitive price, without sacrificing quality.

As we have indicated, we do not include pricing in our overall scoring, but we include it and always suggest our pick for best value.

The Hart was an easy decision for us, it performed exceptionally well in our testing, and is priced the lowest, guaranteeing a seat at the “best value” table. Hart scored in the fourth place in noise, and mid-pack on pretty much all the other categories scored, finishing in 6^th place.

Best Cordless Blower Winner | Milwaukee

Milwaukee 36-volt cordless blower came in first place scoring a total of 20 points. It scored tops in airflow performance, second in features and ergonomics, and fourth in balance.

The Milwaukee operates easily in either user’s hand and has a responsive trigger. Its sturdy base plate doubles as a secondhand grip, and the heads-up battery display is a nice touch. The crew appreciated that there was no boost or turbo button to engage, everything you need comes from the trigger. Milwaukee did suffer in the ergonomic battery scoring category due to the fact that it was the only blower in the lineup with two batteries.  That second battery, while inconvenient, clearly helped push the power and runtime up where it needs to be.

The formidable EGO came in second place with 22 points. EGO scored tops in both ergonomics, features, and the sled thrust test. The EGO was clearly the most powerful of the blowers out of the gate.  The open loop battery control and resulting performance drop over time coupled with the mediocre balance numbers pulled the EGO down from walking away with the top spot.

The EGO is a powerful blower but some users will find that they have to fight to hold it in position, it has a recessed throttle control which the team appreciated. Like Milwaukee, the EGO has a base stand that allows the user to place a two-handed hold for overhead use. Ego also has a nice spring-assisted battery removal feature, which one would not appreciate unless you were testing 15 blowers!

Stihl took third place with 25 points. Stihl took tops in noise and third place in both balance and airflow performance. The Stihl is a robust tool with a nicely designed spring-assist battery removal setup. The team liked that it has an adjustable-length chute, but did not like having to manipulate the awkward safety lever to power it on.

Closing Thoughts

If you’re considering purchasing a blower you should first think about the application, you’re using it for, and then performance. A lot of these blower measurements we shared result in a compromise, so if you want our advice, we feel you should choose a blower that is “stronger for longer.”

Our Head-to-Head tests take time to complete and we are ultimately limited in scope as we’re not a professional testing company. We cannot do long-term testing that would shed light on longevity or durability, and we can’t possibly test every application that you might use a blower for.

We receive a lot of comments about how we arrive at our winner.  We’ve openly shared ALL the data from our tests, and you can rank the tools however you want. In this article, if you hover over the line or column in our graphs, you’ll be able to see the actual values. Hopefully, you’ll find this Head-To-Head useful when comparing compact cordless blowers.

If you have a moment, please check out our other Head-to-Head Tests.

Best Cordless Blower | Head-2-Head Video | 2023

Best Cordless Blower 2023 | Head-To-Head is a post from Tool Box Buzz

Battery-Powered Power Station Head To Head Testing

A 3000-watt portable power supply is a reliable work or home backup power source during a power disruption or outage. These generators can produce enough power to run appliances such as refrigerators, freezers, lights, computers, phones, and yes power tools!

Battery-powered power stations are a viable short-term alternative to gas generators delivering clean, quiet, portable power that is safe to use indoors.

In this Head to Head, we took a look at five portable power stations. Four of them run off of cordless power tool batteries and the fifth has an internal battery. We recognize that there are dozens of internal battery power stations available on the market. We chose one unit to compare but directed our focus to the power supplies geared to the power tool and outdoor power equipment industry.

Power Stations Tested In This Evaluation

Champion 1638-Wh Li-Ion Solar Generator Power Station

• Model – 100594
• Amps – 15
• Peak Wattage: 3200
• Running Wattage: 1600
• Weight: 41.00 lbs
• Battery: Internal 46.8V  35Ah
• Watt Hours – 1628

DEWALT – 1800 Watt Portable Power Station and Simultaneous Battery Charger

• Model – DCB1800B
• Amps – 15
• Peak Wattage: 3600
• Running Wattage: 1800
• Weight: 31.50 lbs
• Batteries: 60 Volt (4) 12.0 Ah
• Watt Hours: 960

EGO Power+ Nexus Portable Power Station

• Model – PST3042
• Amps – 15
• Peak Wattage: 3000
• Running Wattage: 2000
• Weight: 57.60 lbs
• Batteries: 56 Volt (4) 7.5Ah
• Watt Hours: 1680

Milwaukee CARRY-ON 3600with 1800W Power Supply

• Model – 2845-20
• Amps – 15
• Peak Wattage: 3600
• Running Wattage: 1800
• Weight: 42.40 lbs
• Batteries: (4) 18-volt 12.0 Ah
• Watt Hours: 864

Ryobi 40V – 40V 1800 WATT POWER STATION

• Model – RYi1802BTVNM
• Amps – 15
• Peak Wattage: 3000
• Running Wattage: 1600
• Weight: 29.70 lbs
• Batteries: 40 Volt (4) 6 Ah
• Watt Hours: 864

Best Portable Power Station Testing – 7 Scoring Criteria

We designed two performance tests to draw power from these power stations. Additional scoring categories included qualitative evaluations of ergonomics and features, size, and pricing. Lastly, we include a best-value category.

1. Performance Test – Peak Power Test – Evaluated ripping an 8′ long 2×6 pressure-treated lumber, using a 15 Amp, 120V Corded Delta 10” table saw, at a constant feed rate.
2. Performance Test – Run-time – Tested run-time using a 1500 Watt / 15 Amp space heater for power consumption.
3. Ergonomics and Features – Many of these power stations are feature rich. We identified, evaluated, and ranked 13 distinct categories for each power station.
4. Size and Weight – Size matters and weight can get cumbersome. We measured the dimensions and weight of each station as tested (with Batteries).  Given that these are not hand tools, weight was not scored in the final rankings.
5. Best Value –  Oftentimes this category winner tends to resonate with most folks as it combines good performance and price.
6. Price – Price is always an important factor in determining which power station is best for you. We’ve included the current pricing for each of the power stations and batteries “as-tested,” at the time of publication.  We typically do not score pricing in our head-to-head but for this unique test, we determined a Cost per Watt Hour value and used that in our final scoring matrix.

Performance Test – Peak Power Test | Table Saw – DEWALT and Milwaukee

Most of these power stations are designed by tool companies and it is presumed that they can be used on a job site where power is unavailable or indoors where gas fumes from a generator are dangerous.

When considering using power tools with these portable power stations you need to make sure your unit can handle the surge of power the tools use when immediately turned on. This surge is called “Peak Power,” and it is the maximum power that the power supply can sustain for a limited period of time. Peak power differs from continuous power which refers to the amount of energy that the power supply can continuously supply. All power stations have a steady state power output rating as well as a higher rating for peak/startup power.  This test is designed to stress the power station’s peak load capability.

In our testing, we evaluated these units by ripping a 2×6-8′ pressure-treated lumber, using a 15 Amp,  120V Corded Delta 10” table saw. One operator made the cuts at a consistent 2 to 3-second per-foot feed rate.

• The Champion boasts a 3200 Watt start-up rating however, this power station was unable to turn on the table saw without tripping an overload warning and forcing a reset of the power station.
• The Ryobi fared a bit better, capable of powering the saw through a slow feed rate but getting overloaded with a higher rate.  The Power Station also experienced an overload on one of the startups of the saw.
• The EGO had no issues starting up the saw and supplying power through the slower feed rate. The Nexus did however encounter an overload condition during the higher feed rate passes.
• The DEWALT and Milwaukee performed the best and were able to supply the power needed to rip the wood even at the more aggressive feed rate with no overload conditions.

Performance Test – Run-time Test | Heater – Champion

We performed a run-time test with a 120 Volt | 1500 watt electric space heater and an inline power meter and recorded how long the power stations could power the heater.

• The Champion came in at 49 minutes and the EGO at 45 minutes.
• DEWALT and Ryobi followed with 30 and 27 minutes respectively.
• Milwaukee was last with just under 25 minutes.

All of the portable power stations could power the heater at a steady state until the end. There were no gradual drop-offs in power.

The results of the run-time test closely correlate to the advertised Watt Hour (battery capacity or power over time) of each unit as tested.  The Champion has slightly fewer watts Hours than the EGO but was able to power the unit longer.  The other unexpected result is the Ryobi outperforming Milwaukee as they both had the same 864 Watt Hour capacity.

Ergonomics and Features – Winner Ryobi

Typically in our Head-to-Head evaluations “Ergonomics and Features” make up two of the final categories that are scored to determine the overall winner.  We found that the power stations had such a disparity in features that could be important in your purchasing decision, that we have decided to not lump them together in the final scoring allowing each feature significantly more “weight” in the final scoring matrix. We discuss these features and rank each one below.

Carry Handles

The Champion has two, neutral grip handles located on top of the unit. While it is possible to carry this unit with one hand, most users will find it more comfortable using a two-handed carry.

DEWALT has two options for carrying. Option one is a neutral grip, two-handed carry, which DEWALT calls side handles. Option two is a one-handed, suitcase carry, which DEWALT calls the long front handle. When carrying as a suitcase option the back of the unit is smooth, with no protrusions, allowing it to slide against your legs and not catch your pants.

EGO has two neutral grip handles located on top of the unit, when carrying this unit two batteries face the user.  We noted that when carrying the unit against your body, the batteries can easily be dislodged by body pressure. When we looked closer at this – the batteries slide into their ports and do not feature a locking mechanism. Because of this, the unit must stay in its upright position or risk batteries dislodging. While it is possible to carry this unit with one hand, most users will find it more comfortable using a two-handed carry.

Milwaukee has a roll cage with built-in handles for multiple carry options. It also has a padded shoulder strap [sold as an accessory] to help distribute the weight. We found this roll cage allows you to approach the power supply from ANY angle or position and be able to grip it with two hands. While it is possible to carry this unit with one hand, most users will find it more comfortable using a two-handed carry.

Ryobi features a top handle and two pairs of side handle that allow the user to approach and carry this unit from any direction and carry the unit in many configurations. It is also able to be carried one-handed, as a suitcase carry.  Ryobi also has a padded shoulder strap [sold as an accessory] to help distribute the weight.

Display Screen

For status indicators, the Champion unit displays a battery fuel gauge indicator, as well as, a percentage number for battery life. Additionally, the display shows the status of its ports in use. This display does a time-out and requires the user to tap the power button to turn the LED display back on.

We noted that this display has the most information, but is a bit confusing and not intuitive – you WILL need to read the directions.

• DEWALT does not have a status or display screen. It has a green/red LED light at each battery port that indicates a hot battery, low battery charge, hot/cold condition, and charging and charged status.

• EGO has the best balance of being intuitive to operate and provides an easy-to-read and understandable display with useful information, such as; battery status indicators, runtime or charge time remaining, and a total output power meter.
• Milwaukee has a minimal display screen consisting of a very crude 25% increment overall power meter along with a warning indicator for overload and over-temperature conditions.

• The Ryobi display is easy to read but offers minimal information. It includes individual battery levels in 25% increments, and output load levels in both a fuel gauge display and percentage number display. [note – seemed duplicative] It has a session timer clock but could really benefit from a predictive runtime clock like the EGO and Champion displays.

Battery Life Indicator

Champion, EGO, and Ryobi all have LCD displays indicating battery levels and load levels. The EGO also includes a large projected run-time/charge time, which impressed the team. DEWALT and Milwaukee do not have this feature.

Battery Swap While Operating

The Champion has an internal battery and has the capability for parallel connections, allowing it to connect to, and stack up to 10 external batteries or an additional power supply.

The DEWALT and Milwaukee will NOT operate if one of their four batteries is removed. The folks at Milwaukee told us that the decision to do this was based mostly to make the portable power station cost-effective.

Both power stations will turn off if a single battery is disconnected or depleted.  This is important to understand as all batteries are discharged at the same rate.  So if a smaller battery is used amongst larger capacity batteries, the runtime will be limited by the smaller battery.  For this reason, both units recommend using 4 identically sized batteries.

The EGO and Ryobi allow batteries to be swapped in or out without disrupting power. However, if the units are in a high-load demand operation, removing one of the batteries may force it into an overload condition.  They will also operate on any combination or number of batteries.

Pure Sine Wave

Most of these power stations provide pure sine wave power. Pure sine wave inverters prevent overheating and damage to sensitive equipment by providing a more stable voltage and frequency output. Your neighborhood utility provider generates power using only sine waves.

The Champion, EGO, Milwaukee, and Ryobi provide pure sine wave power, but DEWALT does not. The DEWALT offers a modified sine wave type and is NOT recommended for delicate electronics.

The Champion also offers a THD Shield Feature.  THD (Total Harmonic Distortion) Shield will protect sensitive electronics as the power station’s battery levels drop too low and a pure sine wave (<5% THD) cant be maintained, the power station will power down.  This feature can be disabled if powering more robust devices, like the space heater in our run-time test.

Number of AC outlets

We scored the power stations with the most AC outlets higher than the ones with fewer outlets.

• The Champion EGO and Ryobi all have 3 120-volt, 15-amp AC outlets.
• Milwaukee has two 120-volt, 15-amp AC outlets.
• DEWALT has one 120-volt, 15-amp AC outlet.

Number of USB outputs

We’ve all become slaves to charging small devices on the go like our phones and tablets.  USB ports have become the standard for DC charging connections for most personal electronic devices.  Having USB ports on these power stations is a must-have feature, but not all USB ports are created equally.

If you’re not familiar, USB A is the oldest standard rectangular connection that typically delivers just 5V at 2.1A of charging.  These older connections are being slowly phased out in favor of the much smaller, ambidextrous USB C.  Many USB C standards exist and the latest and greatest is the PD or Power Delivery which is capable of 60W fast charging with compatible PD electronics.

• The Champion was also impressive with 2 USB-A 2.1A Ports,  1 USB-C +PD (60W), and 1 USB C QC (Quick Charge 3.0 30W)  port.
• The DEWALT does not have any USB ports, a huge miss in our opinion.
• The EGO has 4 USB ports but unfortunately, they are all just USB A, offering little flexibility.
• Milwaukee only has two USB ports, one USB-A and one USB-C +PD port.
• The Ryobi was the king of USB ports, boasting 4 USB-A 5V 2.1A and  2 USB-C +PD (Power Delivery 60W).

Additional Power Output

The Champion was unique in supplying additional DC power output options.  The unit has a 12V DC, 10A  automobile auxiliary power outlet as well as a 12V DC, 20A APP Anderson Power Pole connector.

Charging Cord / Onboard storage

Can you imagine pulling your power station out in an emergency and the cord was missing?

• Champion supplies a 2-prong, C7 non-polarized connector power cord and plug, also known as a Figure-8 or shotgun connector. This charging cord is fairly common to replace if damaged or lost. The Champion does not have a cord wrap or onboard storage.
• DEWALT does not come with a charging cord but It can be powered by any standard extension cord, with a universal plug.

• EGO comes with a proprietary plug and attached inverter. The plug and inverter are both stored onboard, in a compartment on top of the unit. While we feel having a proprietary cord and inverter is a drawback, the onboard storage compartment is a plus.  EGO also offers a solar panel charger block that can replace the AC block. This solar block is sold as an accessory for $169.

• Milwaukee comes with a 6-foot HD 14 gauge extension cord – a universal plug which we liked.  If the cord gets lost or misplaced, any standard extension cord can charge the unit. Additionally, the roll cage at mid-height has an indentation that was designed to act as a cord-wrap storage feature.
• The Ryobi power cord is proprietary and has no onboard storage. A replacement cord will cost approximately $15 if you lose it.

The team favored the power stations that could be powered by a standard extension cord and plug, as well as, offered on-board cord storage.

Replacing Lost Cords

Champions cord, while not proprietary, could be tough to find a replacement for in an emergency. EGO and Ryobi’s proprietary cords would be even more difficult to replace in an emergency.

Solar Panel Charging

Solar panels and power stations are an interesting conversation.  Having the ability to charge your power station with solar panels is a nice feature and one that many folks with RVs, camps, and off-grid concerns will find valuable.  Contractors on the other hand have limited real estate on the job site space when you consider safety, material, and machine movement.

The Champion comes with an MC4 connector harness to connect up to 3 solar panels. The folks at Champion told us they currently do not offer solar panels as an accessory but recognize that users may want the off-grid charging capability

Built-in light

Only two of the power stations include a light which could be useful in dark areas or during power outage situations.

• Ryobi has a work light with 4 settings: high, low, and a solid or flashing red light for night vision use.
• The Champion has a work light on the front of the unit with a high/low option.

External Power Daisy Chain – Parallel Kit

All the tested power stations have a NEMA 5-15 receptacle which is the standard three-prong household outlet designed to deliver 15A continuous power. A common application for inverter generators is to power an RV, but most common RVs use a 30A plug.  Luckily several of these power station manufacturers have that covered.

Ryobi sells a parallel connection cord as an accessory. It allows users to connect two inverter generators and get twice the power. This parallel kit works with all of Ryobi’s inverter generators and doubles your power output for heavier power needs. It comes as a 120-Volt RV/30 Amp 1RC outlet only.

The Champion has parallel connection capability to increase to 30 Amp power by connecting 2 power stations together or by connecting another ParaLINK-capable inverter to double the power station’s power and add a 120V 30A RV outlet and 120V 30A locking outlet.  It also has the capability to stack up to 10 expansion batteries for a total of 18,018-Wh. Which when combined with solar charging might appeal to off-grid applications.

Pass-Through Power

Pass-Through Power is the capability of the unit to simultaneously charge the unit’s batteries while powering whatever is connected to its AC outlets.  This feature is a common request for those that want to use the unit as a standby emergency generator for important power applications with intermittent or unreliable power sources.  [i.e. sump pump, refrigeration, backup freeze protection]

The Champion was the only unit tested that has Pass Through Power.  Another indicator of its targeted user base.

If you read the reviews on many of these power stations you will learn that many of them intentionally drain the batteries while not in use, but turned on.

Many of these power stations have a “drain down” due to the  Quiescent current – which is a natural draw of the battery over time. Quiescent current only applies if the unit is left on because of the internal “background housekeeping,” and monitoring that these units require.  Due to the lack of passthrough power, if you wanted to leave these units on in some sort of standby function, the batteries would drain over time.

Remote Control

Having the ability to remotely check on power levels and even turn off the unit is a nice feature that two units have through phone apps.

The Ryobi can be controlled through the Ryobi GenControl App.  The App is a well-polished app that works with the majority of Ryobi’s generator lineup.  Once the unit is powered on by hand, the app can be used to turn on and off the AC power plugs as well as remotely shut down the unit.  The battery power levels can be checked as well as the output watts. Some additional features include controlling the onboard LED light as well as the LCD display.

The EGO is the only other unit that has remote connectivity.  The EGO can be controlled by the EGO Power+ app and can be connected via Bluetooth and Wi-Fi.  Having the wifi connectivity can allow you to monitor the unit from almost anywhere.

Security features

While all of the power stations have handles that allow you to use a cable or chain to secure the power station to a stationary object all but two of them could have their expensive batteries removed and stolen. The Champion has an internal battery that automatically protects the battery from theft.

Milwaukee is the only unit that built into their design an anti-theft feature for the batteries. It has a rotating handle that slides over the batteries and exposes a padlock hole. Once the handle is over the batteries they are unable to be removed from the unit.

Size and Volume

The team felt that the space that these units take up is more important than the weight. We ranked the units based on calculated volume and list the weights as tested for your reference. We also calculated their cubic feet for scoring purposes.

The lightest power station was the Ryobi at 28 lbs, followed by the DEWALT at 32 lbs. Champion and Milwaukee were close in weight at 41 and 42 lbs respectively and the EGO was the heaviest at 58 lbs.

With regard to cubic feet, the Champion was the smallest unit at 1.048 cu. ft. The Milwaukee followed with 1.4 cu. ft. followed by the Ryobi with 1.5 cu. Ft. The EGO was the largest unit at 2.8 cu. Ft.

Charging Speed [time]

Note – All of these portable power stations, except the Champion, can double as a cordless battery charger.

The Champion can charge in 4.5 hours from AC wall power and 4.8 with solar-powered DC power. When connected to both AC plus DC charging can be as low as 2.5 hours. We liked that the Champions status screen tells you, based on real-time monitoring,  how much time it will take to charge.

DEWALT takes 6 hours to charge four [4] 12.0 Ah batteries. Like its competitors, it has multi-port, parallel charging, which means it charges all four batteries at the same time, at a charging rate of 2 amps

The EGO takes 12 hours to charge its four [4] 7.5 Ah batteries

Milwaukee pulls 1000 watts from an AC outlet during charging. It takes 4 hours to charge 12 Ah batteries. It charges its batteries simultaneously at a 3 Amp rate [1000 watts]

The Milwaukee unit has simultaneous charging but also evaluates the batteries with the lowest charge and will prioritize charging that pack first. This is because if that pack is depleted the unit will not run. If all the packs are depleted to the same level the charger will simultaneously charge them all at the same rate.

Ryobi charges its batteries sequentially and takes 3 hours to charge one 6.0 Ah battery and 12 hours to charge all 4 batteries. The charger is 80 watts, which is a 2A charge rate for 40V batteries.

Best Price – Winner Ryobi

We scored the portable power station with the batteries we tested them with and included the battery cost.

The Ryobi was the least expensive with a tested price configuration of $1337.  The power station can be sold as a kit with (2) 6.0Ah batteries for $899.  Additional batteries are $219 a piece. The bare unit price is currently $749.

The Champion does not have external batteries and the unit cost is $1499.99

The Milwaukee is not sold as a kit and the unit cost is $699.  The 12.0 Ah batteries tested each run $249 driving the as-tested cost to $1695.

The EGO was tested with (4) 7.5 Ah batteries.  The Power Station can come as a kit with two 7.5Ah batteries for $999.  The two additional batteries are $399 a piece, with an as-tested price of $1797.

The DEWALT like Milwaukee does not get sold as a kit and a bare unit will cost $529. The 12.0Ah batteries are each $319 costing a total of $1805

It’s important to remember that to operate the DEWALT and Milwaukee you will need ALL 4 batteries. The EGO and Ryobi do not require all of the batteries to operate.

Price Per Watt Hour – Winner Champion

We stated earlier that the runtime test results closely correlated to the total Watt Hour rating of each power station.  To aid in seeing how far your purchasing power is going to battery capacity and therefore, expected runtime, we calculated the Price per Watt Hour for each station and the batteries tested.

Again, the Champion took top honors in this ranking with a $.92 / Wh value.  The most interesting result is that of the EGO station, which was just slightly higher at $1.07/Wh.  The EGO had a much better bang for the buck result than the other 3 removable battery platform contenders.

The Ryobi finished in third place with a $.1.55 / Wh value. DEWALT finished at $1.88/Wh, and Milwaukee at $1.96/Wh.  These two cost over double the Champion when just considering battery capacity.

Best Power Station

Our usual modus operandi is to crown one winner as Best in Class winner. With this particular head-to-head, we quickly learned, that portable power supplies are designed to meet different and specific needs. We evaluated and scored four categories for you to consider:

• Best Emergency Portable Power Station
• Best Jobsite Power Station
• Best All Purpose Power station
• Best Value Power Station

Best Emergency Portable Power Station – Winner Champion

The Champion portable power station scored 36 points and was designed as a “ground up,” portable power station, and it clearly shows!

It crushed the other power stations in the features, price, and runtime testing categories.

The Champion is a compact, feature-packed portable backup battery solution ideal for RVing and camping, tailgating, or as an emergency indoor generator during a power outage.  As good as it is, it is NOT suitable for job site use.

Best Jobsite Power Station – Milwaukee

The Milwaukee scored 48 points overall beating DEWALT with 56 points. The DEWALT and Milwaukee were clearly both designed to run power tools on the job site. They both crushed the table saw performance test.

The DEWALT lost place due to its featureless design. Milwaukee has more features than DEWALT but suffered in runtime due to its relatively lower total Watt Hour capacity.

“Milwaukee’s minimalist but robust design was meant to be dropped, kicked, and survive on the job site” ~ Jeff

Of the two power stations, Milwaukee is able to run with pure sine wave energy allowing tradespeople to run their electronics to view plans on job sites.  The Milwaukee with four 12 Ah batteries will cost $1,695 while the DEWALT, in the same configuration, costs $1,805.

Best ALL PURPOSE  Portable Power Station  |  Ryobi

This category is where we chose the winner based on all-around value and usefulness, not solely on score. Ryobi came in second place overall with 39 points. EGO was just one point behind with 42 points.

The Ryobi is very feature-rich, winning the Ergonomics and Features Combined Category.  The 40V battery platform is a rapidly expanding exciting lineup from Ryobi and the power station is a great addition.

The Ryobi is the lightest of the stations and reasonably compact. The abundance and quality of the USB ports were a team favorite and lastly, the Ryobi can be paired up  [parallel connected] with a gas or battery generator to double its power to 30 amps – something that will get RV users’ attention.

Best Value – Winner EGO

Best value is often a popular category as it highlights contestants that performed well at a lower purchase cost.

But the EGO was the second most expensive unit. While that may be true, its the Cost/Watt Hour conversation that really brings the EGO value to the front.  The EGO boasted the highest Watt Hour rating with 1680WH, almost doubling that of the Ryobi and Milwaukee.  The kit price of the EGO with two 7.5 AH batteries is just $999, and that brings its runtime capability just shy of the Milwaukee, Ryobi, and DEWALT for a significantly lower cost.

The EGO power station tells you how much time it takes to charge its display which is an awesome feature.  The team liked that it allows for battery swap while operating and offers 2000 continuous watts / 3000 peak watts

The EGO was neck and neck in this testing with the Ryobi, finishing just one point behind with 42. Both were feature rich and clearly designed for non-job site user experience.

Conclusion

These Power Stations and their batteries are expensive investments.  Some of these units had great features but likely none are going to be able to sway you to a new battery platform if you already have batteries of a certain brand that could drastically reduce the purchase price of the systems. If you’re not already invested in a battery platform, you may want to look closer at stand-alone, internal battery platforms like the Champion.

These tests take time to complete and are ultimately limited in scope as we’re not a professional testing company.

We cannot do long-term testing that would shed light on durability and we can’t possibly test every application that you might use one of these power stations for.

We get lots of comments about how we make the final rankings. We’ve openly shared ALL the data from our tests, and you can rank the tools however you want. Hopefully, you’ll find this Head-To-Head useful when comparing compact portable power stations.

If you have a moment, please check out our other Head-to-Head Tests.

Portable Power Station Head To Head Test Video

Best Portable Power Supply 2023 is a post from Tool Box Buzz

Best Cordless Impact Driver

There’s no doubt that Impact Drivers have completely changed the construction industry and drastically improved both productivity and quality. Impact drivers allow users to install screws, structural fasteners and small bolts more efficiently than a drill. Impact drivers drastically reduce broken fasteners, stripped screw heads and costly delays. An impact driver relies on a hammer and anvil mechanism to deploy rotational force when fastener resistance is encountered.   

In our Best Cordless Impact Driver Head-To-Head test, we’ve selected 19 full-size impact drivers from a wide range of manufacturers. We invited all of the major manufacturers to participate, with some brands sending multiple impact drivers.

 

Features Qualitative Scoring Results
MFG	Score	Rank
Bosch	1	1
Makita 18v	2	2
Makita 40v	2	2
Skil	2	2
Festool	3	5
FLEX	3	5
Kobalt	3	5
Metabo HPT 18DC	3	5
Metabo HPT 18DBD	3	5
Metabo HPT 36v	3	5
Milwaukee	3	5
Ridgid	3	5
Ryobi	3	5
DEWALT	4	14
Hilti	4	14
Metabo 18 LT	4	14
Metabo 18LTX	4	14
FEIN	5	18
Hart	5	18

WP DataTables

Best Size and Weight | Winner DEWALT

Size matters to users, in this case, they want a smaller, compact impact driver that still has the power for the applications they need to deploy it in. Compact also means that the tool can be used in more situations, think of tight spot applications like sistering floor joists with a 5 or 6-inch fastener,  in between joist bays. We felt the two most important factors for an impact driver were the weight and head length.  Having a lightweight tool when working overhead, coupled with a compact size that can fit into small openings is a huge win.

To determine a final ranking for size and weight, each driver was weighed without the battery and the head length, from bit holder/collet to back was measured.  Each of these values were ranked separately and then combined into a single factor to determine the winner.   The DEWALT was the most compact impact driver of the bunch. It measures 3.9″ and weighs 2.1 lbs and is 1/2″ smaller than the 2nd place Metabo HPT 18DC  which measures 4.51 inches and measures 2.0 lbs.  Third place was the Makita 18V measures 4.53  inches and weighs 1.9 lbs.

An interesting fact is that all of the tools weigh from 1.9 lbs. to 3.3 lbs.

MFG	Length (in)	Weight (lb)	Rank
DEWALT	3.94	2.10	1
Metabo HPT DC	4.51	2.00	2
Makita 18v	4.53	1.90	3
Milwaukee	4.48	2.20	4
Makita 40v	4.77	2.20	5
Metabo 18V LTX	5.10	2.10	6
Ridgid	5.02	2.20	7
Festool	5.17	2.12	8
Metabo HPT 36v	4.52	2.50	8
Hilti	5.44	2.20	10
Skil	4.92	2.47	10
FLEX	4.68	2.70	12
Kobalt	5.27	2.40	12
FEIN	6.00	2.20	14
Metabo HPT DBD	5.04	2.90	15
Hart	5.82	2.50	16
Ryobi	5.60	2.55	16
Metabo 18 LT	5.64	2.60	18
Bosch	5.82	2.60	19

WP DataTables

Best Cordless Impact Price  | Winner Skil

Price is undoubtedly an important consideration when buying tools, especially for those of you who are just starting out in the trades. We can certainly agree on that and also agree that the majority of contractors have strong brand loyalty and would rather continue with their current battery platform than venture out and create a new line of cordless power tools.

We did not include the price in our scoring criteria but included bare tool pricing for you to use as needed.

The best-priced impact driver was the  Skil coming in at $69.99 bare tool. The second lowest price was the Hart at $77.85 and the third was the Bosch at $99.00. The team all agrees that the Skil and Hart impact drivers fall into the DIY category for users.

There are several pro-grade impact drivers in this test, I’ll use the Festool as an example. In their research and testing Festool found that the most frequent failure point on impact drivers was the anvil mechanism, so they adjusted the shape and material hardness of their anvil to increase the lifespan of the tool. They also decreased the internal strike speed (BPM) so it was less likely to break.

Festool also incorporated a longer trigger which allows for finer control of the variable speed trigger making it easier to manually control slow speed on hardware attachment. The moral of the story here is that pro-grade tools are designed to last longer, for us PROs a tool is an investment that is needed for our livelihood – invest wisely!

Best Cordless Impact Driver Head-To-Head | 2023 is a post from Tool Box Buzz

Best Cordless Reciprocating Saw (36V-60V) Head-To-Head

Piggybacking off of our recent Best 18-24 volt Cordless Reciprocating Saw Head-to-Head, we wanted to bring out the big boys. We put high-capacity reciprocating saws, ranging from 36 to 60 volts up against each other to crown the Best “High Capacity” Cordless Reciprocating Saw.

Cordless Reciprocating Saw Line Up

Unlike the previous 18-24v Cordless Reciprocating Saw Head-To-Head, only four saws met the “high capacity” criteria ranging from 36-60V. Below are the four saws and their specifications.

DEWALT

• Model: DCS389B
• Voltage: 60V
• Stroke-Per-Minute: 3000 SPM
• Stroke Length: 1-1/4″
• Weight: 8.65 LBS
• Price: $269

Makita 36v (18V x 2)

• Model: XRJ06Z
• Voltage: 36V (2 x 18v)
• Stroke-Per-Minute: 3000 SPM
• Stroke Length: 1-1/4″
• Weight: 9.3 LBS
• Price: $239

Makita 40V XGT

• Model: GRJ02Z
• Voltage: 40V
• Stroke-Per-Minute: 3000 SPM
• Stroke Length: 1-1/4″
• Weight: 9.9 LBS
• Price: $279

Metabo HPT

• Model: CR36DAQ4
• Voltage: 36V
• Stroke-Per-Minute: 3000 SPM
• Stroke Length: 1-1/4″
• Weight: 8.4 LBS
• Price: $199

Head-to-Head Testing Format

Our team used and ranked the same nine criteria for our Best “High Capacity” Cordless Reciprocating Saw test as we did on our 18v-24v Head-to-head testing.

When considering relevant trade tests, we chose three that hit the mark for remodeling contractors, electricians,  plumbing and heating contractors which mirror the 18v-24v testing we just completed.  In addition to the standard testing criteria we typically use, these tests make up the total rankings and allow us to pick a clear winner.

1. 1. Gas Pipe Cutting for Plumbing / Heating Contractors
   2. Uni-strut Cut Test for Electricians
   3. Nail Embedded Cut Test for General Contractor / Demolition
   4. Features
   5. Ergonomics
   6. Size
   7. Noise
   8. Price
   9. Best Value

The Best “High Capacity” Cordless Reciprocating Saw was decided based on the sum of each of the first seven categories.

Testing Blade Information

All reciprocating saws were fitted with task-specific, new Milwaukee Nitrus Carbide blades before testing, shifting the focus away from the variation between different blades and toward the differences between the individual  saws.

• Timed Test 1:  Gas Pipe for plumbers.
• Timed Test 2:  Uni-strut for electricians.
• Timed Test 3:  Nail Embedded Wood for Carpenters and Remodelers.

Milwaukee asserts that the NITRUS reciprocating saw blades are made with 25% more carbide, cuts faster, and last longer than conventional carbide-toothed blades.

Battery Pack Guidelines

For this Head to Head, we requested manufacturers send us two of their batteries in the 4.0 Ah to 6.0 Ah range. This was to even out the playing field as some companies offer very large batteries for these saws.

Testing Format Information

Jig Information

For the Gas Pipe cutting test, a custom saw-holding jig was used.  To reduce human error in some of our testing, the Tool Box Buzz crew spends countless hours designing, constructing, and fine-tuning our test jig.

The jig is made up of 4 extruded aluminum towers that serve as vertical rails for a mounting platform that holds and restrains the saw to guarantee a repeatable even cut. A fractal vise clamp mold themselves around the saw’s irregular surfaces and generate even horizontal clamping force, with hold-down straps creating additional support.

The jig utilizes a timing mechanism that uses two strategically placed micro switches to regulate the start and stop times of the cut. The micro-switch timing starts as soon as the cut is initiated and just after the blade passes through the last of the material. The cutting force applied to the cut is approximately 25 lbs, which included the variable weight of the saw and the mounting platform.

Gas Pipe Speed Test | Winner – Makita 40V

Plumbing and heating contractors are the core users for this gas pipe test. We used  1-1/2′′ diameter schedule 40 black steel gas pipe for the material. A new Milwaukee 6″ Torch blade was fitted onto each saw and used to make three timed cuts.  An average of the three cuts was used for scoring.  To hold the pipe at the proper height while we cut, we used Rockwell Jawhorses.

The winner of the gas pipe test was the Makita XGT 40V with an impressive average time of 3.55 seconds. Second place was the Metabo HPT with a time of 5.73 seconds. Third, was the DEWALT Flexvolt at 6.10 seconds. The slowest saw of the four was the Makita 36V coming in at 11 seconds even.

Uni-strut Speed Test | Winner – Makita 40V

The winner of this test was the Makita XGT 40V with a speed of 2.70 seconds. Metabo HPT in a close second with 3.01 seconds. Third place went to the Makita 36V at 3.54 seconds. Finishing out the saws was the DEWALT Flexvolt at 5.40 seconds.

Nail Embedded Wood Speed Test | Winner – Makita 40V

Three 2×10 joists were fastened together and tested with fifteen (15) nails total inserted in the wood for our nail-embedded wood test. With each cut, we refreshed the nails and used the same 10 lb weight and cut method.

This “torture test” simulates heavy-duty demolition cutting for carpenters, remodelers, and general contractors. In each saw, we utilized a new Milwaukee WRECKER (9″ 6 TPI with Nitrus Carbide Teeth) –  48-00-5272, blade suited for nail-embedded wood, and timed three cuts.