Freewheel removal tool FR-1.2 (this doesn't work!)

thingiverse

I'm making an FR-1.2 freewheel removal tool for a bicycle, trying to get it right from scratch. The dimensions in my design are spot on, but I quickly realized that removing a freewheel requires way more torque than the material can handle. My first try was with PLA, hollowed out to save time and printed vertically. It slipped into the wheel easily with just a few taps of a hammer, but when I applied some force, it broke instead of slipping. A Dremel helped me clean up the mess from the broken tool stuck in the wheel. For my second attempt, I switched to ABS and printed horizontally for added strength. This time, I made the model solid and was able to apply more force without breaking. However, the material still gave way when I pushed too hard. The verdict is clear: this tool isn't feasible with current materials yet. Removing a freewheel requires a steel tool that can handle the high torque involved. Luckily, you can find a suitable tool on eBay for around $5 - just be prepared to wait a bit for it to arrive. My designs include both hollow and solid versions of 1" socket and square tools. **Edit 1:** I updated my design to use two M4 bolts today. Unfortunately, they sheared under the pressure. Maybe using bigger bolts made from harder material will do the trick next time?