How to make a DIY bolt puller tool: Doodad 4.0 updated instructions + shopping list

I had a bit of aluminum plate leftover from the optional step so I cut out a hex piece and brazed it onto the end. 

Aaand just realized why that makes the whole thing unusable!

Will be drilling out a larger hole in the brazed-on endcap. 

This makes a good low cost handle and can do double duty for other wrenching tasks.

I pulled this 3/8" stainless bolt and it eventually snapped off in tension, what a testament to how much force this thing can generate!

Look at the plastic flow, thread distortion, and necking on this remnant.

The steel hex cap (McMaster 94818A036) seems to have been discontinued. Please reply if anyone has found a suitable replacement. The closest substitute I could find was this speed nut, though it will require modification (need to grind out the ID).

https://www.mcmaster.com/92043A610/

Franky, Gregg and I were posting about that just above. He suggested a washer, I wound up using a piece of the leftover aluminum. It's also not strictly necessary but, I've tried using the puller without it and it does mushroom the end of the tube a bit, which is OK if you file it down when it gets bad. 

Franky Lapitinowrote:

The steel hex cap (McMaster 94818A036) seems to have been discontinued. Please reply if anyone has found a suitable replacement. The closest substitute I could find was this speed nut, though it will require modification (need to grind out the ID).

https://www.mcmaster.com/92043A610/

Hi Franky,

I made a bunch of doodads recently, and tried to use those caps. They didn’t work at all. What Greggerman shows up thread with the nylon ball seems pretty slick! I didn’t use that but have played with drilling out nylon barstock, which worked OK.

For a couple extra bucks, cutting down a 1 inch six point socket works pretty well (idea stolen from Alex R) and if thoughtful when using the doodad, not having any end cap also works.

Update: the speed nut works, you need a hammer and something to use as a punch to flatten out the little tabs. And also a rotary tool to grind out the middle a bit.