This Instructable will show you how to build/ machine your own bike crank removal tool from SCRATCH and for under 3.00 $!!
I know that Park Tool has their own crank removal tool but, WHAT IF you want to make your own??
Step 1: Materials & Tools
•1.375 inch x 1" Dia 6061 aluminum solid round
•.125 inch x .5 Dia 1045 mild steel solid round
•2 inch x 5/16 - 18 Grade 8 bolt
•Metal lathe (thread cutting ability)
•Round End mill - (5/8)
Step 2: Machining!
•Cut your 1.375 inch long by 1" Dia of 6061 aluminum with a hacksaw or horizontal bandsaw.
•Place the stock Al in the lathe and face off both sides of the piece with a facing tool.
•Turn down .75 inches to .8661 (22mm)
•Drill and tap a 5/16 x 18 inch hole .5-.75 inches from "necked down" end.
•Cut "wrenching" flats
Step 3: Threading!
•Make sure you present a 60º single point cutter perpendicular to the work piece!! Also make sure the tool is on center height.
•Set up your machine for 1mm threads. The Major diameter is 22mm or .8661 inches. Thread for about .375-.5 inches .
Step 4: Filing!
•Use a hacksaw and square or rectangle files to make the wrenching flats. OR you could use an end mill in a milling machine!
Step 5: Machining the Plug
•Since this plug piece is what the screw must push against (so that you don't wreck your BB threads) it must be make out of a high carbon steel so that it won't deform or "mushroom" under pressure.
•It needs to be .5" x .125" with a "dish" cut using a ball end mill.
Step 6: Using It!
•In order to use the crank removal too you must first remove the bolt that holds your crank to the Bottom Bracket. If you have square taper or ISIS (International Splined Interface Standard) your plug must be made to fit ( different diameters).
•NOW, just place the plug into the crank bolt hole (dish out), then screw in the remover tool, and use a 3/4 wrench to tighten it down, then use a 1/2 ratchet to push/pull the crank off!
Also check out my MONSTER chain instructable!
P.S. Please vote for me for the Bike Contest!! (if you are so incline)