BUILD A BOLT EXTRACTION TOOL.

These instructions detail how to build a “Doodad”, which is a extraction tool created By Greg German. Thanks to Greg for all his work rebolting and exploring techniques to extract old bolts.

Doodad 4.0 shopping list :

• Order from AliExpress
  

  • ($20.68 + $3.89 shipping) RDB BEARING AND MECHANICAL PARTS -
    SFU1605 300mm Ball Screw + *custom engineering diagram above*. Mention the custom 1/2-20 thread and the m10 thread on the back end in a note after you order

  • ($2.00 + 5.26 shipping) aluminum wrench as handle (many available: search AliExpress or Amazon for '6-68mm wrench')

• Order from McMaster-Carr

  • ($9.85 for 12") cut to 8.5". AL Hex tubing with 1/8" wall thickness: https://www.mcmaster.com/9063T34/

  • ($1.88) 5/8" Stop collar: https://www.mcmaster.com/6432K18/

  • ($2.17) thrust bearing: https://www.mcmaster.com/2879T33/

  • ($3.14) Grade 8 washer : https://www.mcmaster.com/98026A117/

  • ($0.78 at the hardware store) 1/2-20 nylock jam nut: https://www.mcmaster.com/90101A255/

  • ($0.35 at the hardware store) Thumb screw 1/4-20 https://www.mcmaster.com/90181A537/

    • drill a 3/16" hole near the top of the tubing and tap it with a 1/4-20 tap. You might need to shorten the thumb screw.

    • If you are lazy or don't want to do that, skip the thumb screw altogether and just drill a diagonal hole and thread a coat hanger thru it so the tube can't fall off.

Your Doodad now costs you $50.00 plus some shipping.

Stop there if you are on a budget and want the cheapest possible tool. 

Optional stuff to make the Doodad better below. (Or you could literally just use duct tape instead for both of these items if that floats yer boat) -

• ($11.00 for pack of 5) Steel hex cap, designed to snap over a 3/4" nut: https://www.mcmaster.com/94818A036/

  • ($0.08/each at the hardware store) #2 x 3/16"L blunt screws (x2-3): https://www.mcmaster.com/90056A075/

  • Notes: This will keep the end of the aluminum hex tubing from getting mushroom-shaped over time. The steel cap is oversized, so you'll need to rotate it so that the holes are closer to the points of the hex tubing. That will keep the 3/4" hole centered.

• ($7.25 - or $0.15/ea at a scrap yard like Alreco in Brighton) 3" diameter 12 gauge (0.081" thick) aluminum disc- https://metalremnants.com/product/aluminum-discs/

  • ($0.12/each) 1/4-20 x 0.75" L pan head screws (x2) + 2 wing nuts or nylock nuts

  • Notes: Drill 1/4" holes thru the triangular inset in each of the crescent wrench jaws. Adjust the crescent jaws to fit the ball nut, then drill 1/4" holes thru the 3" disc of aluminum below. Screw the wrench to the disc and you've got a handle that also reinforces the total strength of the wrench.

Now your Doodad costs you about $68.95

You still need these:

• Pulling 3/8" wedge bolts:

  • ($8.95/each) Reducing coupling nut, 3/8-16 to 1/2-20: https://www.mcmaster.com/91072A166/

    • note: you need to modify it by drilling out the unthreaded middle portion to at least 0.410" but less than 0.500" so that the reverse set screw in the SDS adapter can function as a backstop. Otherwise, the old bolt will ruin this coupling nut on the first use.

  • ($6.29 for 3) SDS drill chuck adapter: https://www.amazon.com/COMOK-2-Inch-Thread-Keyless-Adapter/dp/B07JHKWWDY

• Pulling 3/8" 5-piece bolts:

  • ($1.71/each) 3/8 draw stud x 4.00"L : https://www.mcmaster.com/90281A640/

  • ($6.90) 3/8-16 heavy duty spiral tap: https://www.msdiscounttool.com/catalog/product_info.php?csv=gg&products_id=97398

• Pulling 1/2" 5-piece bolts:

  • (~$4.40/each - might have to buy 10- check auto parts stores to purchase singles) draw stud: https://www.dormanproducts.com/p-22486-675-038.aspx?

  • ($11.23) coupling nut 1/2-20 to 1/2-13: https://www.mcmaster.com/98434A116/

  • ($10.50) 7/16-20 spiral tap: https://www.msdiscounttool.com/catalog/product_info.php?cPath=1103&products_id=97401