Making a special socket for Water Chiller

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At the Kitchener Rangers  /  Erie Otters  hockey game Friday night I was asked by a Refrigeration Mechanic Service Technician “Chiller Expert” Johnson Controls if I could make a tool to remove the 5/8 hex nuts from a cooling chiller door. Apparently from the drawing and explanation he gave me, if a 1 1/16 deep socket is used there is no room between the outer door frame lip and the milled stud to allow the socket to come straight out and is on an angle resulting in the milled stud being bent as the nut is backed out. Therefore a lot of stress is allpied to the nut and the milled stud, bending the stud and damaging the thread on both the stud and nut.
The solution would be a socket that would be deep enough to allow the stud to enter the socket but yet shallow enough to allow the socket to completly remove the nut from the stud threads without damaging the stud or the nut and reduce the stress of all mechanical parts and the mechanic.
This is where I come in.
By the way, the Rangers lost the game.

photo 1

The drawing was simple and easy to understand, I am used to these drawings. the Mechanic also supplied the sockets, 1 Proto 7434H 1 1/16" and 2 Proto 7322H 11/16" sockets and a 5/8 nut.

photo 2

The sockets are very hard and I wanted a thin accurate cut. I chucked the 1  1/16" socket and set up my Dremel. using my home-made mount.

photo 3

With the Dremel spinning at 30,000 Rpm and the lathe at whatever I started feeding in the cross slide. The rag over the lathe bed ways is to collect and protect my lathe from abrasive materials.

photo 4

You can see how far the Dremel EZ456 thin cut wheel has entered the cut. Also seen here is the the EZ402 Mandrel.

photo 5

The the wheel has just cut through to the internal hex shapes, it won't be long now. Approximately 6 minutes to this point.

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photo 6

Then using the Dremel 8193 Aluminum Oxide Grinding Wheel to chamfer the inside edge copying the original socket.

photo 7

Here are all the parts. and believe or not, the cutting wheel on the left is the wheel I used and the one on the right is a new wheel. Never under-estimate the ability of the Dremel or its products.

photo 8

I found some heavy washers 2" by 1/2" and 1/8" thick. welding the washers to the hex end of the 11/16" socket. I only have a Lincoln stick welder and I am not a proficient welder but I got the job done.

photo 9

Back to the lathe, I trued the washer face and machined a tiny sholder to center the socket, you can see the socket fits nice and snug.

photo 10

Maching the weld splatter and gobs of weld from the socket it looks better.

photo 11

Cleaning up the finished product and a little paint to help cover mistakes, It doesn't look too bad. Lets hope it works. The remainder of the 1  1/16" socket may also be of use, I machined out the centre so it would better accept the nut.

photo 12

Here it is plain to see the importance of having the proper tools to do the job.

photo 13

With a tight area like this to manouver, having a proper designed socket and extention is the answer.

photo 14

Tight squeeze here.

photo 15

If you go back to photo 1 or photo 7 and examine the cardboard blueprint it is easily seen why a deep socket will jamb the nut and bend the stud.

photo 16

Here the mechanic demonstrates his excellent design efforts.

photo 17

Notice the nice clean hands and fingernails of this mechanic. It is evident he uses his brains more than his hands.
Editors Note
There are three types of people in this world,
Those that make things happen,
Those that watch things happen and,
Those that wonder what happened.

I have been using Dremel tools since the 1970"s and have many jigs and adaptors where I can use the Dremel to help me with the many tasks in keeping the shop run smooth.   As example I made a jig to hold the Dremel to sharpen the carbide tipped blade on my table saw with out removing the blade. Another application is touching up the highspeed steel or carbide cutter bits on my metal lathe without removing the bit.
I have plans on making a jig to resharpen the bandsaw blade on the saw but just haven't had time. The Dremel has helped me a great deal when rebuilding the Walker Truck with the many rusted bolts and screws, and so many of these are located in difficult to reach areas.

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