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Modified punch tool for removing front spindle nut
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61Scout
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PostPosted: Sun May 28, 2017 3:03 pm    Post subject: Modified punch tool for removing front spindle nut Reply with quote

Here's a handy tool. It's a modified 5/32" punch. I simply took a 5/32" punch to the grinding wheel at a very aggressive angle to make this tool. Occasionally I dress it with a file or at the grinding wheel.

This tool is used to remove the front spindle nut. Simply tap it into where the nut is locked down and drive it down. The modified punch will follow the groove in the spindle and press out the lock cleanly to where you can unscrew the nut by hand. One should never remove these nuts with an impact gun or ratchet, doing so can damage the threads on the spindle and make the new nut difficult to put on. This modified punch makes the job super simple and it's incredibly easy to make.

5/32" modified punch profile:
Image may have been reduced in size. Click image to view fullscreen.


Ready to work:
Image may have been reduced in size. Click image to view fullscreen.



-Kevin
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1986 Westfalia Weekender Wolfsburg, RJE 2.3
1985 Tin Top, Subie 2.2 + 5MT
Floppy Mirrors no more: http://www.thesamba.com/vw/forum/viewtopic.php?t=653018&highlight=
Remove the front spindle nut with ease: https://www.thesamba.com/vw/forum/viewtopic.php?t=679567&highlight=
Remove the rear wheel bearing housing without messing with the big 46mm nut: https://www.thesamba.com/vw/forum/viewtopic.php?t=679507&highlight=

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djkeev Premium Member
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PostPosted: Sun May 28, 2017 3:39 pm    Post subject: Re: Modified punch tool for removing front spindle nut Reply with quote

The level of genius that resides in these forums is awesome!!!

I use an old screw driver but this is so much better.


Thanks

Dave
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ALIKA T3
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PostPosted: Sun May 28, 2017 3:57 pm    Post subject: Re: Modified punch tool for removing front spindle nut Reply with quote

A 27mm eye wrench is plenty to overcome the punch, but this is way cleaner indeed.

You're supposed to not re-use the nut anyway. I've done it if it ends up on a different punch location.
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61Scout
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PostPosted: Sun May 28, 2017 6:40 pm    Post subject: Re: Modified punch tool for removing front spindle nut Reply with quote

ALIKA T3 wrote:
A 27mm eye wrench is plenty to overcome the punch, but this is way cleaner indeed.

You're supposed to not re-use the nut anyway. I've done it if it ends up on a different punch location.


I had a van a few months ago that had damaged threads on the spindle. Looking at the naked spindle the grove goes well into the threads. Though I can't know for sure, my guess is that someone locked the crap out of it and then also zipped it off with a gun without even trying to undo the lock. It felt rough coming apart. Luckily I was able to use a thread file to clean up the threads.

The one in the picture is locked correctly, just at the end. But this tool works on the nuts that a gorilla locked down too. All I can say is try it for yourself. If you don't like it, grind the punch flat again. But I'd also wager that if you do make one, you'll leave it that way and use it again. If you can get a little ice-cream scoop profile in the grind that works best, but a flat grind works too. This tool really does work like a dream.

I never reuse the nut, but I've heard of guys swapping out left to right and being able to get a different lock down point on the nut.

-Kevin
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1986 Westfalia Weekender Wolfsburg, RJE 2.3
1985 Tin Top, Subie 2.2 + 5MT
Floppy Mirrors no more: http://www.thesamba.com/vw/forum/viewtopic.php?t=653018&highlight=
Remove the front spindle nut with ease: https://www.thesamba.com/vw/forum/viewtopic.php?t=679567&highlight=
Remove the rear wheel bearing housing without messing with the big 46mm nut: https://www.thesamba.com/vw/forum/viewtopic.php?t=679507&highlight=

-Nec Spe, Nec Metu


Last edited by 61Scout on Mon May 29, 2017 9:38 am; edited 1 time in total
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ALIKA T3
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PostPosted: Sun May 28, 2017 10:52 pm    Post subject: Re: Modified punch tool for removing front spindle nut Reply with quote

Yeah def gorilla work, the punch location is outwards from the threads, so it cannot supposedly hurt them.

I probably won't make one until I encounter the need for it but I do admire your ingenuity in tool making . It is a way you see things and how you address a problem. That's brilliant Smile

Aloha!
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epowell
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PostPosted: Wed Jun 21, 2017 1:57 am    Post subject: Re: Modified punch tool for removing front spindle nut Reply with quote

Inspiring, THANKS!
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bobbyblack
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PostPosted: Wed Jun 21, 2017 6:56 am    Post subject: Re: Modified punch tool for removing front spindle nut Reply with quote

Nice piece of work! When I first started reading the post, I had already imagined what the picture would look like. Then I saw the image, and it struck me as an opportunity lost due to my idea that the process would put the nut back into round. In my head I had the flat side of the tool placed against the spindle, and letting the rounded side work the nut back out to round. Seems like the machining of the spindle has the flat edge built in.

EDIT:

Needs clarification. Found two images that now make me wonder if I was seeing things when I looked at my spindles... these images from other users seem to show two different kinds of machining on the spindle ends!

Rounded:
Image may have been reduced in size. Click image to view fullscreen.


Flat:
Image may have been reduced in size. Click image to view fullscreen.

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61Scout
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PostPosted: Wed Jun 21, 2017 9:07 am    Post subject: Re: Modified punch tool for removing front spindle nut Reply with quote

Hey all. Just wanted to do a quick update and show the companion tool to this one. This is the tool I use to create the peen on the end of the axle nut. It's a 3/16" punch with a straight slot cut in the end from a cut off wheel. It's perfect for catching the lip of the nut and doesn't move around when you peen it down. It keeps the peen right at the end of the spindle shaft (where it should be and not over the threaded portion) and also won't mess up the spindle or split the nut like a chisel might. Here it is:

Image may have been reduced in size. Click image to view fullscreen.


Image may have been reduced in size. Click image to view fullscreen.


As bobbyblack correctly noted, the groove at the end where the nut gets peened is round/curved. Thanks for posting that! This is why a modified punch is so effective at driving the peen off of the nut. It's like a little ramp. The slot on the side shown in the second picture he posted is where the washer keys into.

-Kevin
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1986 Westfalia Weekender Wolfsburg, RJE 2.3
1985 Tin Top, Subie 2.2 + 5MT
Floppy Mirrors no more: http://www.thesamba.com/vw/forum/viewtopic.php?t=653018&highlight=
Remove the front spindle nut with ease: https://www.thesamba.com/vw/forum/viewtopic.php?t=679567&highlight=
Remove the rear wheel bearing housing without messing with the big 46mm nut: https://www.thesamba.com/vw/forum/viewtopic.php?t=679507&highlight=

-Nec Spe, Nec Metu
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bobbyblack
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PostPosted: Wed Jun 21, 2017 9:34 am    Post subject: Re: Modified punch tool for removing front spindle nut Reply with quote

Kevin/61Scout:

Great follow-up, thanks! I'm going to swing out the the local Farm Store on lunch, get a 5/32'nd, a 3/16'th and a couple brass drifts!

I might mod your mod tho... Perhaps creating an oval instead of one round and one flat sides.

Great thread!

-bobby
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61Scout
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PostPosted: Wed Jun 21, 2017 11:36 am    Post subject: Re: Modified punch tool for removing front spindle nut Reply with quote

bobbyblack wrote:
Kevin/61Scout:

Great follow-up, thanks! I'm going to swing out the the local Farm Store on lunch, get a 5/32'nd, a 3/16'th and a couple brass drifts!

I might mod your mod tho... Perhaps creating an oval instead of one round and one flat sides.

Great thread!

-bobby


If a 5/32" punch can't be found, a 3/16" one should work for the unpeening punch too. Not sure I'd go much larger than that however since the tip of the punch does have to get down deep sometimes to unpeen the nut. For the peening punch, the size would be far less critical since it's only working from the outside. It's really just whatever is handy.

One note/tip about the unpeening punch... Be gentle when using it. I mean, don't just go full on gorilla and pound it down. Light taps then pull it out, light taps then pull it out... use some oil for lube, check the nut often. The last thing a guy would want to do would be to get it stuck or worse yet break off the tip down in the groove. That would be like dealing with a broken tap, a complete PITA for anyone who has dealt with one. So use caution and go slowly. Dress the tip if it starts looking rough.

As far as modding my mod... well, whatever works. I understanding trying to work the nut back into shape. But of course once the unpeening process has started the tool can simply be flipped over. Then the flat side would be on the spindle and the round side would be towards the nut. Or perhaps just modify a third punch. I think you can pick up a set at HF for around $10... or yard sale, grandpas tool box, and so on.

-Kevin
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1986 Westfalia Weekender Wolfsburg, RJE 2.3
1985 Tin Top, Subie 2.2 + 5MT
Floppy Mirrors no more: http://www.thesamba.com/vw/forum/viewtopic.php?t=653018&highlight=
Remove the front spindle nut with ease: https://www.thesamba.com/vw/forum/viewtopic.php?t=679567&highlight=
Remove the rear wheel bearing housing without messing with the big 46mm nut: https://www.thesamba.com/vw/forum/viewtopic.php?t=679507&highlight=

-Nec Spe, Nec Metu
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