OK- I must have missed this thread so I'll try to catch up. I'll mostly echo what others have said already but I'll try to add a few of my experiences.
Can you cheat and come in from both sides when you get to a thick point or will i just need some mega bar
It will be very hard to make a pass from each side and get them to consistently match up. Your better off with a longer bar especially since you already have the powerhead to pull it.
Maybe i should start smaller and work my way up then it will be easier to get a system down and when i move up to really wide slabs i will have some theory behind me.
The very first CSM I built and used was a 72". If I can do it, anyone can. Just put your study time in here and use your head and you will be fine.
About the chains... Most modern chains have heavy bodies for liability reasons. Take, for instance, Stihl chain. If you look closely at most of their .058 or .050 gauge chains, you will find that all the components of the chain are actually .063 ga with only the tang (the part that rides in the bar grove) stamped down in thickness to the stated gauge.
so a 3/8 pitch on a 50 guage bar is going to have the same kerf as a 3/8 pitch chain on a 63 guage bar because pitch is what dictates kerf? … They don't put the bigger cutters of the same cutter type on a larger guage?
Short answers- yes,no. Long answer- the cutters are the same on chains of similar pitch regardless of gauge. I’ve measured many different chain styles, pitches, gauges, grind angles, etc. and found the only variable that has a consistent measurable effect on kerf width is pitch. On average, .404 produces a 3/8” to 7/16” kerf, 3/8” produces a 5/16” to 3/8” kerf and .325 runs 5/16” or slightly less (I have not tried LP but it won’t hold up to a 120cc saw anyway). There are many other factors that can affect these results such as chain tension, bar wear, grind angles, etc., etc. but the magnitude is relatively small (provided you don’t have several of them working together). You can drive your self mad worrying about these things but you shouldn’t when starting out. They all work, some just marginally better than others.
Personally, I use full-comp semi-chisel .325 .063 ga. for my 44” bar/ 084 mill. It holds up well and cuts noticeably faster and smoother than 3/8”. On my 66” and 72” bars, I typically use 3/8” ripping chains because .325 stretches too badly. If I have a suspicion there may be metal present, I’ll use 3/8” on the 44” and .404 on the longer bars because they are less likely to break.
Hope I didn’t add to the confusion.