Introduction: Bicycle Headset Cup Remover

Picture of Bicycle Headset Cup Remover

This is a mimic of a much more expensive tool sold by Park tools to remove headset cups out of bicycle frames. Theirs is all pretty and made of high tensile steel, but whatever.

Find some tubing. Copper, steel, even an old flat handlebar will work. Just don't use aluminum; it's too brittle.

Step 1: Cut Your Tubing Down the Center

Picture of Cut Your Tubing Down the Center

Cut down about 5 or 6 inches through both sides. A hack saw will work too.

Step 2: Stretch Apart

Picture of Stretch Apart

Clamp your tube into a vise and using something, separate the ends.

Step 3: Make It Look Like This

Picture of Make It Look Like This

It should be about 1.5" wide

Step 4: Remove a Cup

Picture of Remove a Cup

If you wish to remove the bottom cup, insert your tool (non-cut side first). Pull on the top until your flared out bottom rises just above the cup you're removing and hear it pop.

Step 5: Wail

Picture of Wail

Now, holding the frame securely, wail down on it. Bigger harder hits are better. If you tap tap tap on it, you'll get nowhere other than harming your newly crafted tool.


russ_hensel (author)2016-09-01

Just a note to let you know I have added this to the collection: Difficult Dis-assembly: Taking Things Apart for Repair


There are a lot of things that are hard to take apart and lot of methods.

Malhecho (author)2012-12-24

i got some emt just chillin around the house i will make me one.

2al (author)2012-03-11

Perfect ! I want to powder coat my frame and therefore was pondering about a way remove the damn cups... But then i got suddenly lazy came over to the ever so marvelous instructables. Once again this attitude proved to be faster than thinking ;-)

Thanks a lot.

skaterqwertyuiop (author)2011-08-26

PS. What was your diameter of the copper pipe?

skaterqwertyuiop (author)2011-08-26

Haha, making one of these today. I'm not spending $27 on a tool that i'm going to use once. And i'm sure as hell not paying my LBS $20-$30 to do it for me. Thanks for making this instructable.

callmeshane (author)2007-10-28

Ahhh the principle of bearing extraction.....

I use small light taps, in the 12 o'clock, 3, 6, 9, 12 etc... to slowly screw the bearing out in an almost perfectly straight fashion.


This eliminates stretching and deformation of the head stem, that comes with whacking the bearing out, mostly on one side.


mcvarij (author)2007-10-27

freakin' sweet. i thought about this, but took no action. good to see someone did.

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