DIY Cog removal tool

[Gordon]

If someone has already documented this, I apologize.
Parts needed: clutch, 1 inch grade 2 nut and one 2 3/4 inch long grade 8 bolt with nut and washer.
Procedure: Weld clutch to 1 inch nut. Thread driver into clutch and fasten with the 3/8 bolt. Hand tighten. Put the assembly in a vice and apply chain whip to cog. Bolt keeps the driver from turning out of the clutch. When I started I was using grade 2 bolts but they kept breaking.
Cost of materials: I had a clutch. The1 inch nut and 3/8 bolt w/washer and nut cost me a dollar at the hardware store where they sell them by weight. A local welder charged me $5 so my total cost was $6.

 

[Commish1969]

Thank you Gordon! Worked like a charm! -Andy

 

[mpdoan2]

This looks pretty cool; I’d love to see a video of the removal.

 

[FastEddie]

Thank you for posting this! I've learned about this on this site but can't afford $300 for an old beat up original so now I'm off to my "friend with a welder" to get this done!

 

[srfndoc]

Another Gordon repro here, works great:

 

[Kickstand3]

I’m going to make one , looks easy !

 

[srfndoc]

I have a bunch of the nuts I used for this tool (in combination with a driver) if anyone wants one. I'll bring them to the next Cyclone Coaster ride or Orange Circle ride if there is interest. Think I had to buy a bag of 10 to get this size.