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Headlamp switch removal - homemade tool
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old_n_slo
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PostPosted: Wed Mar 24, 2010 4:25 pm    Post subject: Headlamp switch removal - homemade tool Reply with quote

This fabricated washer will remove your headlamp and washer controls from your dash without damage. Sure, go ahead and continue to use your needle nose pliers......or...

1. Grab a 9/16" washer from your bucket 'o fasteners.
2. With the edge of a file (or hacksaw) open up a gap.
3. File or Dremel a small relief where the pencil is pointed so it follows the curvature of the circular dash control nut.

Twist and shout!

The details:

a) Carefully pick your washer to ensure the correct "width"
b) Use a 15/64" drill to "gauge" your opening. That will be the size of the headlight switch shaft.

You know about using a nail to hold the shaft still, while twisting the knob to remove...right?

Enjoy!


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BWD
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PostPosted: Wed Mar 24, 2010 4:35 pm    Post subject: Reply with quote

Nice tip, beats the hell out of $20 something! Cool
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&Dan
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PostPosted: Wed Mar 24, 2010 4:51 pm    Post subject: Reply with quote

Pretty frickin' great!

How many other homemade VW-specific tools are out there?
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Cusser
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PostPosted: Wed Mar 24, 2010 8:49 pm    Post subject: Reply with quote

Didn't someone take a nut driver and grind down the two sides leaving two little "pegs" ?
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andk5591 Premium Member
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PostPosted: Thu Mar 25, 2010 2:57 am    Post subject: Reply with quote

I like this - I had seen coupling bolts ground to have the 2 nubs - but nut driver idea is good too. Aren't we freakin geniuses? LOL. Good post - thanks
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runamoc Premium Member
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PostPosted: Thu Mar 25, 2010 6:47 am    Post subject: Reply with quote

Quote:
but nut driver idea is good too


X2, wonder about the 'inside' hole of the driver being large enough for the 'shaft'?
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Raul_MX
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PostPosted: Thu Mar 25, 2010 6:51 am    Post subject: Reply with quote

Can you please post a picture of the finished tool and while in use?

Regards.
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BajaCapt
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PostPosted: Fri Mar 26, 2010 9:15 pm    Post subject: Reply with quote

Hey! thanks for this post, I doing a search for headlight switch removal and ran into it, gave me a good idea to go about it.
I made my own tool out of a butter knife, I used a dremmel with a cut off wheel and a sanding bit for finishing it off, works like a charm! Cool

The tool and the things need it to make it ( about 20 minutes as well)
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glutamodo Premium Member
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PostPosted: Fri Mar 26, 2010 10:39 pm    Post subject: Reply with quote

Here's my home-made tool, made from a piece of stainless pipe:

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kolt10
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PostPosted: Fri Mar 26, 2010 11:16 pm    Post subject: Reply with quote

this is great. i was able to twist two of my mine off with my thumbs but i have one that i cant get. I will use this tomorrow.
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kolt10
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PostPosted: Fri Mar 26, 2010 11:21 pm    Post subject: Reply with quote

actually...im not now gonna make the tool. just used snap ring type pliers and they worked to fit in the slots
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andk5591 Premium Member
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PostPosted: Sat Mar 27, 2010 10:40 am    Post subject: Reply with quote

Made the washer tool yesterday since I was installing a light switch - worked great - and if I lose it, not biggy. Thanks
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Buck Naked
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PostPosted: Sat Mar 27, 2010 11:09 am    Post subject: Reply with quote

I think I hear the theme to `MacGyver` in the back ground. Laughing Seriously these are some great ideas thanks for info.
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old_n_slo
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PostPosted: Sat Mar 27, 2010 1:27 pm    Post subject: Reply with quote

If you need some more "gription" on the washer for torque, avoid the temptation to use pliers. They could slip and....well, I won't be responsible for scratches.

Vice grips.
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grandpa pete
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PostPosted: Sat Sep 20, 2014 5:11 pm    Post subject: Reply with quote

or grind down an 8 mm deep socket Shocked
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Aynthm
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PostPosted: Sat Sep 20, 2014 11:11 pm    Post subject: Reply with quote

Know how those little nuts that hold down the single port intake pipes are a bitch to get on and off due to the limited room and the lip on the bracket? Well I picked these nuts up at ACE and you can use a rachet on 'em, removal and installation is a snap.

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AlohaFlyer
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PostPosted: Fri Dec 05, 2014 2:47 am    Post subject: Reply with quote

I made that tool and I am still having trouble getting those nuts to move... the previous owner painted the car without removing them, so I think that is partly why they won't move. I am afraid of stripping them... any ideas on how to get these to come off?

Thanks
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diablosandwich
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PostPosted: Fri Dec 05, 2014 5:36 am    Post subject: Reply with quote

Could you get some more torque if you used a tool like this?http://www.thesamba.com/vw/classifieds/detail.php?id=841285 instead of a small washer?
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AlohaFlyer
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PostPosted: Mon Dec 08, 2014 7:05 pm    Post subject: Reply with quote

diablosandwich wrote:
Could you get some more torque if you used a tool like this?http://www.thesamba.com/vw/classifieds/detail.php?id=841285 instead of a small washer?


I just ordered that tool... thanks for the idea. I will let you know how it goes.

Mahalo,

RP
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hitest
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PostPosted: Mon Dec 08, 2014 7:48 pm    Post subject: Reply with quote

I always just used needlenose pliers (the small 2-1/2" kind from cheap tool sales at gun shows). It moves the gripping surface out where an adult hand can hold it. I still have to be careful though.
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I wonder what the nut looks like.



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