{"id":10327,"date":"2018-12-19T21:02:33","date_gmt":"2018-12-20T02:02:33","guid":{"rendered":"https:\/\/www.kwbugclub.org\/armaturenbrett\/?p=10327"},"modified":"2018-12-19T21:02:33","modified_gmt":"2018-12-20T02:02:33","slug":"diy-head-removal-tool","status":"publish","type":"post","link":"https:\/\/www.kwbugclub.org\/armaturenbrett\/diy-head-removal-tool\/","title":{"rendered":"DIY: Head Removal Tool"},"content":{"rendered":"<p>I&#8217;ve started a new project for my bug this winter.\u00a0 I think I&#8217;ve committed to building a new engine.\u00a0 It&#8217;s a costly project, and to save some money where I can, I&#8217;d like to be able to re-use some parts from an engine that I acquired.<\/p>\n<p><!--more--><\/p>\n<p>The issue that I&#8217;ve been having with the donor engine is the fact it&#8217;s not run in many years, and has been subject to the elements, like sitting outside uncovered, ever so gently rusting&#8230;.<\/p>\n<figure id=\"attachment_10329\" aria-describedby=\"caption-attachment-10329\" style=\"width: 1600px\" class=\"wp-caption alignleft\"><img loading=\"lazy\" decoding=\"async\" class=\"wp-image-10329 size-full\" src=\"https:\/\/www.kwbugclub.org\/armaturenbrett\/wp-content\/uploads\/2018\/12\/IMG_20181027_1625365.jpg\" alt=\"\" width=\"1600\" height=\"1200\" srcset=\"https:\/\/www.kwbugclub.org\/armaturenbrett\/wp-content\/uploads\/2018\/12\/IMG_20181027_1625365.jpg 1600w, https:\/\/www.kwbugclub.org\/armaturenbrett\/wp-content\/uploads\/2018\/12\/IMG_20181027_1625365-300x225.jpg 300w, https:\/\/www.kwbugclub.org\/armaturenbrett\/wp-content\/uploads\/2018\/12\/IMG_20181027_1625365-768x576.jpg 768w, https:\/\/www.kwbugclub.org\/armaturenbrett\/wp-content\/uploads\/2018\/12\/IMG_20181027_1625365-1024x768.jpg 1024w\" sizes=\"auto, (max-width: 1600px) 100vw, 1600px\" \/><figcaption id=\"caption-attachment-10329\" class=\"wp-caption-text\">Figure 1 &#8211; just a tad crusty<\/figcaption><\/figure>\n<p>&nbsp;<\/p>\n<p>&nbsp;<\/p>\n<p>Care must be taken when heating hardware that goes into the magnesium case. Magnesium has a bit of a problem of catching on fire when it&#8217;s heated.<\/p>\n<p>After the pulley and all the engine cooling tin was removed, it was time to remove the cylinder heads.\u00a0 The only way I knew to remove them was to remove the 8 nuts, and strike the head with a rubber mallet directly to the fin edges.\u00a0 If you do not strike the fins on edge, you risk breaking a fin. &#8220;Not cool for an air cooled engine!&#8221;<\/p>\n<p>I had no luck removing the heads as they are completely corroded in place.\u00a0\u00a0 I needed to find a new technique.\u00a0 I stumbled across a post over at &#8220;The Samba&#8221; entitled &#8220;<a class=\"maintitle\" href=\"https:\/\/www.thesamba.com\/vw\/forum\/viewtopic.php?t=391652\">Removing crusty heads<\/a>&#8220;.\u00a0 As the title sounded promising, it\u00a0 showed a home-made tool for removing the heads from a 36hp.\u00a0 I figured I could build same for my 1600.<\/p>\n<figure id=\"attachment_10336\" aria-describedby=\"caption-attachment-10336\" style=\"width: 889px\" class=\"wp-caption alignleft\"><img loading=\"lazy\" decoding=\"async\" class=\"wp-image-10336 size-full\" src=\"https:\/\/www.kwbugclub.org\/armaturenbrett\/wp-content\/uploads\/2018\/12\/Screenshot_20181107-2005252.png\" alt=\"\" width=\"889\" height=\"1279\" srcset=\"https:\/\/www.kwbugclub.org\/armaturenbrett\/wp-content\/uploads\/2018\/12\/Screenshot_20181107-2005252.png 889w, https:\/\/www.kwbugclub.org\/armaturenbrett\/wp-content\/uploads\/2018\/12\/Screenshot_20181107-2005252-209x300.png 209w, https:\/\/www.kwbugclub.org\/armaturenbrett\/wp-content\/uploads\/2018\/12\/Screenshot_20181107-2005252-768x1105.png 768w, https:\/\/www.kwbugclub.org\/armaturenbrett\/wp-content\/uploads\/2018\/12\/Screenshot_20181107-2005252-712x1024.png 712w\" sizes=\"auto, (max-width: 889px) 100vw, 889px\" \/><figcaption id=\"caption-attachment-10336\" class=\"wp-caption-text\">Figure 2 &#8211; 36HP tool as seen on The Samba<\/figcaption><\/figure>\n<p>&nbsp;<\/p>\n<p>I happened to have all the stuff I needed, so I started to building a set.\u00a0 I altered the design a bit.\u00a0 The original design (above) would use a wrench to turn the nut, causing the length of the threaded rod to increase.\u00a0 In my design (below), I fixed the nut at the cylinder end of the tubing.\u00a0 I welded a nut on the head end of the all-thread, like a very long bolt. This will allow me to put a ratchet (or air ratchet) on the tool and hopefully pull the heads off with ease. (ha-ha!).<\/p>\n<p>The welding is a little crude, but I think the tool will work ok. I slapped some gold paint on the tool because,\u00a0 who doesn&#8217;t love gold paint?\u00a0 If they work out, I&#8217;d like to be able to use them again in the future.<\/p>\n<p>I&#8217;ll let you know if the engine continues to fight me.<\/p>\n<figure id=\"attachment_10333\" aria-describedby=\"caption-attachment-10333\" style=\"width: 1600px\" class=\"wp-caption alignleft\"><img loading=\"lazy\" decoding=\"async\" class=\"wp-image-10333 size-full\" src=\"https:\/\/www.kwbugclub.org\/armaturenbrett\/wp-content\/uploads\/2018\/12\/IMG_20181219_1909423.jpg\" alt=\"\" width=\"1600\" height=\"1200\" srcset=\"https:\/\/www.kwbugclub.org\/armaturenbrett\/wp-content\/uploads\/2018\/12\/IMG_20181219_1909423.jpg 1600w, https:\/\/www.kwbugclub.org\/armaturenbrett\/wp-content\/uploads\/2018\/12\/IMG_20181219_1909423-300x225.jpg 300w, https:\/\/www.kwbugclub.org\/armaturenbrett\/wp-content\/uploads\/2018\/12\/IMG_20181219_1909423-768x576.jpg 768w, https:\/\/www.kwbugclub.org\/armaturenbrett\/wp-content\/uploads\/2018\/12\/IMG_20181219_1909423-1024x768.jpg 1024w\" sizes=\"auto, (max-width: 1600px) 100vw, 1600px\" \/><figcaption id=\"caption-attachment-10333\" class=\"wp-caption-text\">Figure 3 &#8211; New Build &#8211; shown completely &#8220;cranked down&#8221; (head hopefully removed by the time they are cranked down like this)<\/figcaption><\/figure>\n<p>&nbsp;<\/p>\n","protected":false},"excerpt":{"rendered":"<p>I&#8217;ve started a new project for my bug this winter.\u00a0 I think I&#8217;ve committed to building a new engine.\u00a0 It&#8217;s a costly project, and to save some money where I &hellip; <\/p>\n<p class=\"link-more\"><a href=\"https:\/\/www.kwbugclub.org\/armaturenbrett\/diy-head-removal-tool\/\" class=\"more-link\">Read more<span class=\"screen-reader-text\"> &#8220;DIY: Head Removal Tool&#8221;<\/span><\/a><\/p>\n","protected":false},"author":2,"featured_media":0,"comment_status":"open","ping_status":"open","sticky":false,"template":"","format":"standard","meta":{"_editorskit_title_hidden":false,"_editorskit_reading_time":0,"_editorskit_is_block_options_detached":false,"_editorskit_block_options_position":"{}","_crdt_document":"","footnotes":""},"categories":[13,33,6,34,7,31,14,18,15,16,17],"tags":[],"class_list":["post-10327","post","type-post","status-publish","format-standard","hentry","category-air-cooled","category-buggy","category-engine","category-rail","category-repair","category-tool","category-type-1","category-type-181","category-type-2","category-type-3","category-type-4"],"yoast_head":"<!-- This site is optimized with the Yoast SEO plugin v27.5 - https:\/\/yoast.com\/product\/yoast-seo-wordpress\/ -->\n<title>DIY: Head Removal Tool - K-W &amp; Area Bug Club<\/title>\n<meta name=\"robots\" content=\"index, follow, max-snippet:-1, max-image-preview:large, max-video-preview:-1\" \/>\n<link rel=\"canonical\" href=\"https:\/\/www.kwbugclub.org\/armaturenbrett\/diy-head-removal-tool\/\" \/>\n<meta property=\"og:locale\" content=\"en_US\" \/>\n<meta property=\"og:type\" content=\"article\" \/>\n<meta property=\"og:title\" content=\"DIY: Head Removal Tool - K-W &amp; Area Bug Club\" \/>\n<meta property=\"og:description\" content=\"I&#8217;ve started a new project for my bug this winter.\u00a0 I think I&#8217;ve committed to building a new engine.\u00a0 It&#8217;s a costly project, and to save some money where I &hellip; Read more &quot;DIY: Head Removal Tool&quot;\" \/>\n<meta property=\"og:url\" content=\"https:\/\/www.kwbugclub.org\/armaturenbrett\/diy-head-removal-tool\/\" \/>\n<meta property=\"og:site_name\" content=\"K-W &amp; Area Bug Club\" \/>\n<meta property=\"article:publisher\" content=\"https:\/\/www.facebook.com\/KWBugClub\/\" \/>\n<meta property=\"article:published_time\" content=\"2018-12-20T02:02:33+00:00\" \/>\n<meta property=\"og:image\" content=\"https:\/\/www.kwbugclub.org\/armaturenbrett\/wp-content\/uploads\/2018\/12\/IMG_20181027_1625365.jpg\" \/>\n<meta name=\"author\" content=\"Mark Brown\" \/>\n<meta name=\"twitter:card\" content=\"summary_large_image\" \/>\n<meta name=\"twitter:creator\" content=\"@kwbugclub\" \/>\n<meta name=\"twitter:site\" content=\"@kwbugclub\" \/>\n<meta name=\"twitter:label1\" content=\"Written by\" \/>\n\t<meta name=\"twitter:data1\" content=\"Mark Brown\" \/>\n\t<meta name=\"twitter:label2\" content=\"Est. reading time\" \/>\n\t<meta name=\"twitter:data2\" content=\"2 minutes\" \/>\n<script type=\"application\/ld+json\" class=\"yoast-schema-graph\">{\"@context\":\"https:\\\/\\\/schema.org\",\"@graph\":[{\"@type\":\"Article\",\"@id\":\"https:\\\/\\\/www.kwbugclub.org\\\/armaturenbrett\\\/diy-head-removal-tool\\\/#article\",\"isPartOf\":{\"@id\":\"https:\\\/\\\/www.kwbugclub.org\\\/armaturenbrett\\\/diy-head-removal-tool\\\/\"},\"author\":{\"name\":\"Mark Brown\",\"@id\":\"https:\\\/\\\/www.kwbugclub.org\\\/armaturenbrett\\\/#\\\/schema\\\/person\\\/36fb7afeec0b13eabad95240c06bc8a5\"},\"headline\":\"DIY: Head Removal Tool\",\"datePublished\":\"2018-12-20T02:02:33+00:00\",\"mainEntityOfPage\":{\"@id\":\"https:\\\/\\\/www.kwbugclub.org\\\/armaturenbrett\\\/diy-head-removal-tool\\\/\"},\"wordCount\":449,\"commentCount\":0,\"publisher\":{\"@id\":\"https:\\\/\\\/www.kwbugclub.org\\\/armaturenbrett\\\/#organization\"},\"image\":{\"@id\":\"https:\\\/\\\/www.kwbugclub.org\\\/armaturenbrett\\\/diy-head-removal-tool\\\/#primaryimage\"},\"thumbnailUrl\":\"https:\\\/\\\/www.kwbugclub.org\\\/armaturenbrett\\\/wp-content\\\/uploads\\\/2018\\\/12\\\/IMG_20181027_1625365.jpg\",\"articleSection\":[\"Air Cooled\",\"buggy\",\"engine\",\"rail\",\"repair\",\"tool\",\"Type 1\",\"Type 181\",\"Type 2\",\"Type 3\",\"Type 4\"],\"inLanguage\":\"en-US\",\"potentialAction\":[{\"@type\":\"CommentAction\",\"name\":\"Comment\",\"target\":[\"https:\\\/\\\/www.kwbugclub.org\\\/armaturenbrett\\\/diy-head-removal-tool\\\/#respond\"]}]},{\"@type\":\"WebPage\",\"@id\":\"https:\\\/\\\/www.kwbugclub.org\\\/armaturenbrett\\\/diy-head-removal-tool\\\/\",\"url\":\"https:\\\/\\\/www.kwbugclub.org\\\/armaturenbrett\\\/diy-head-removal-tool\\\/\",\"name\":\"DIY: Head Removal Tool - K-W &amp; 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