Every time I've done an oil change on my van myself, I've had trouble changing the oil filter.
The reason is that to replace it you need to unscrew the cap, on top of which there is a hexagonal protrusion similar to a nut. Unfortunately, I do not have a suitable socket wrench, and for these purposes I used an adjustable or socket wrench, or a combination of both. The whole difficulty lies in the fact that in a limited space it is quite difficult to apply enough force to unscrew the lid.
Therefore, I decided to make a key designed specifically for this task.
What you will need
Tools:
- - welding machine for electric arc welding.
- - angle grinder.
- - other tools (file, wire brush, hammer...).
Materials:
- - a small metal plate 8 mm thick (probably thinner, but not less than 5 mm).
- - metal pipes (20 and 25 mm in diameter, about 40 cm in length each).
Cutting metal strip
The first thing to do is measure the length of the edge of the hexagon for which you need to make a key.
We multiply this size by six (the number of edges), and we get the length of the metal strip that needs to be cut.
I recommend adding 6 mm to the resulting length (which I didn’t do), then it will be easier for you at the next stage of manufacturing.
The plate should be wider than the height of the bolt for which you are making the key (a couple of millimeters is enough).
When everything has been measured, cut off the strip.
Next, draw lines on it, between which there should be a distance equal to the length of the edge plus one millimeter.
Then you need to make cuts along the lines, going deep to 2/3 of the thickness of the plate.
The result should be a strip of metal that looks like a chocolate bar.
Giving a hexagonal shape
At this stage, it will be more convenient to work if the metal is heated. (I did not maintain a constant temperature and was unable to bend the entire piece in one piece).
Clamp the strip in a vice at the level of the previously made recess.
Use a hammer to bend the section protruding from the top of the vice.
Check if the angle fits by trying it on the corresponding nut.
Repeat for each segment.
As my strip cooled, the metal became more difficult to work with. This led to a breakdown over the third segment. In my case, this worked to my advantage, because when I started bending the fourth section, it turned out that its length was not enough and I needed to grind off a little metal so that the nut would fit properly. (I think adding a millimeter to each cut will help avoid running out of length on the inside edge of the key).
So I got a part consisting of two parts, each with three sides. (It may be easier to work with this than with a solid piece curved into a ring, as I originally planned to do).
Check that the workpiece fits properly onto the nut. But not too tight.(If necessary, you can grind off part of the inner surface of the edges)
Welding hexagonal shape
Now all that remains is to weld the part into one. (In my case I used a 2.5mm welding electrode)
After this, you need to try on the nut again, and if everything fits, you can fill the cuts with welding. (3.2 mm electrode).
We try to put it on the nut again, because the high temperature during welding can deform the metal.
(This time I additionally tried the blank on the hexagonal protrusion on the filter...)
After this, you can clean up all the excess, making the shape of the part smoother.
We weld the lid
After sanding, place the piece on the sheet of metal from which the strip was made and trace its outline on it.
I chose to draw the line along the inside, adding a couple of millimeters along the edges. But you might want to outline the part around the outside, on the contrary, removing the extra couple of millimeters.
Then we weld the resulting upper part onto the previously made part. (We use 2.5 mm and 3.2 mm electrodes)
Let's check again if everything fits.
Pipe welding
Only after this step can the result of the work be called a tool.
I simply welded a pipe on top of the resulting part (it turned out to be suitable for my single-purpose wrench).
And then after fitting the key to the van's filter cover, I welded the handles to the pipe. (They are made from a smaller diameter pipe cut in half).
I welded them at an indirect angle, so it will be easier for me to work. (If I had secured the handles at 90 degrees, I would have hit the hood latch with my knuckles as I rotated).
After sanding and brushing, I spray painted the key black.
Now everything is ready.
Application
This socket wrench has a fairly clear purpose.
It makes changing the oil filter a pleasure.
But I think the way I made the tool can be applied to any other bolts and nuts that are in hard to reach places.
The manufacturing method is quite simple. The work does not take much time (I did it in 3 hours), and the key is quite cheap, even if you buy all the materials in the store. I think that after this project, I will make more such instruments in the future.
I hope you enjoyed it. Thank you for your attention!
Original article in English
