Cutting down a Snap On Allen Socket

[DPDISXR4Ti]

I recently purchased a 1/2" drive 8mm Allen socket (p/n SAM8E) for the primary purpose of removing the rear caliper bracket bolts from an Audi A4. They are notoriously difficult to remove, both for the tight access and the inhuman force required to remove them.

Because of the tight clearance, a "stubby" socket is needed, but Snap-on and others only make a short version in 3/8" drive, not 1/2". I want to use my 1/2" breaker bar.

Long story short, I want to cut down the length of the bit on the socket. Any issue doing that? Will a standard, good quality, hack-saw blade do the job?

 

[rlitman]

I would expect a quality allen socket to be too hard to be cut with a hack saw. I've cut allen keys with an abrasive cutoff wheel, but you'll want to dip them frequently in water to keep from ruining the temper.

 

[R. Johnson]

When I did mine I used an allen key with a small pipe for leverage.

Sent from my SM-G930V using Tapatalk

 

[bmwpowere36m3]

Hacksaw.... no. Cut-off... yes Do it in stages (don't overheat the bit).

 

[dr_clyde]

Use an abrasive cut-off wheel.

 

[md21722]

Yeah just use a cutoff wheel. I have cut down Snappy gold colored bits before to work on German cars. Or buy a German hex driver. I prefer Hazet/Stahlwille drivers for hex, XZN, etc...

 

[Heavy Metal Doctor]

Long story short, I want to cut down the length of the bit on the socket. Any issue doing that? Will a standard, good quality, hack-saw blade do the job?

No issue at all. I've done it with a few SO drivers. Clamp the driver in a vice and use a 4" cut-off wheel to grind through it - hold it a s straight / square as you can so it's doesn't look like **** when you're done.

 

[afazz]

To echo the comments above, cutting it down with an abrasive tool isn't much of a problem as long as you keep it from overheating. I also doubt a hacksaw would cut it.

If you're interested in keeping it Snap-on, I wonder if you could pop an FAMXS8E2 replacement bit into your SAM8E socket?

 

[shawhite]

Why not just replace the Allen portion with a stubby one. I bet your snap on guy will do it for free.

 

[stage20]

Why not just replace the Allen portion with a stubby one. I bet your snap on guy will do it for free.

 

[md21722]

I find that the German tool makers are better at this stuff. Their hex drivers are always shorter than what you get from Snap On.

Stahlwille 54-8 only $9. It may fit:
http://www.ebay.com/itm/351955784059

Hazet 985-8 $26.60. A true 1/2" stubby that will certainly work:
http://www.ebay.com/itm/like/360731709736?lpid=82&chn=ps&ul_noapp=true

 

[leg17]

Plain Allen wrench with a cheater pipe.

 

[M6erfan]

I find that the German tool makers are better at this stuff. Their hex drivers are always shorter than what you get from Snap On.

Hazet 985-8 $26.60. A true 1/2" stubby that will certainly work:
http://www.ebay.com/itm/like/360731709736?lpid=82&chn=ps&ul_noapp=true

If you need 1/2" drive, it's hard to do any better than that...

 

[DPDISXR4Ti]

Stahlwille 54-8 only $9. It may fit:
http://www.ebay.com/itm/351955784059

That one is 60mm long, which is pretty nearly the same as the Snap-On.

Hazet 985-8 $26.60. A true 1/2" stubby that will certainly work:
http://www.ebay.com/itm/like/360731709736?lpid=82&chn=ps&ul_noapp=true

At 38mm length, that one would work. It's priced about the same as the
ASSENMACHER AHS 3049-8
http://www.autotoolworld.com/Assenm..._126175.html?gclid=CM2Mu_6PytECFYmLswodQW8DjQ

I'm just not sure I want to spend $25 for another tool I'll use so infrequently.

 

[DPDISXR4Ti]

Plain Allen wrench with a cheater pipe.

Yea, that was suggested to me. A 3/8" cast iron pipe would be the one to try, I'm just not sure I trust that solution.

 

[RAYJAY]

PIECE OF 8MM HEX cut to your length of choice and a 8 mm 1/2 drive socket epoxy hex in socket if needed
we do it at work all the time

 

[DPDISXR4Ti]

I would expect a quality allen socket to be too hard to be cut with a hack saw. I've cut allen keys with an abrasive cutoff wheel, but you'll want to dip them frequently in water to keep from ruining the temper.

I think this will be the route I go. Thanks for all the feedback.

 

[gdocktor3]

If an Allen wrench with a pipe will work, why not use the stubby 3/8" drive with a breaker bar and a pipe on that?

Edit: I thought you already had the stubby 3/8 drive socket. Try the Allen wrench before cutting the expensive Snap On bit. No?

 

[DPDISXR4Ti]

If an Allen wrench with a pipe will work, why not use the stubby 3/8" drive with a breaker bar and a pipe on that?

I considered that (pretty sure it would require a 1/2" pipe), but I haven't got a good quality 3/8" drive breaker bar. I could much more readily justify that purchase though, so you may be on to something.

 

[DPDISXR4Ti]

Edit: I thought you already had the stubby 3/8 drive socket. Try the Allen wrench before cutting the expensive Snap On bit. No?

I actually don't need a stubby for the 3/8" socket since the head of the 3/8" breaker bar is smaller.

 

[T45]

Just buy the stubby bit for $10 bucks. You can easily cut the good snap on bit, but use a bandsaw and cut the end you are not going to uses. Then re-hammer the bit in (good side facing the work+do not overheat). But that just wastes a bit...same process and use the stubby bit and you have choice of two working bits. :

https://store.snapon.com/Hex-Stubby-mm-chrome-3-8-quot--Bit-Metric-Hex-Stubby-8-mm-P651568.aspx

 

[md21722]

Another thing I do in tight clearance areas is use a serpentine belt tool. This is similar to what the other poster is saying bout the flat stock. The serpentine belt tool is basically flat stock with a 3/8" (or 1/2") drive head welded on. Often it gives just that extra bit of clearance that you need.

 

[Heavy Metal Doctor]

I have a number of cut off allen wrench pieces I use for very tight spots -- slip the little stub into the bolt (or hydraulic system port plug as is often the case for my work) and then use a regular wrench on it.

 

[Ign]

I've machined sockets in the lathe w zero issue. I'd be surprised if a quality carbide insert wouldn't cut it easily.

VIM makes some nice stubby hex, affordable too.

 

[Tim37]

The bits running about $10 off the truck you could buy a stubby bit and put in it.

Or hell I'm with ya I would cut it short. I have had them round off and I just used a cut off wheel and chopped a little off the top so I could keep on working my so guy was ok with it

 

[MShaw]

"A 3/8" cast iron pipe would be the one to try,"

No, black iron. Cast iron would snap like a toothpick.

 

[sberry]

This is an 8 mm tool, does it need 1/2 drive? How often do you do this?

 

[KnurledNut]

OP, why are you removing the bracket?

 

[Cope]

This is an 8 mm tool, does it need 1/2 drive? How often do you do this?

From OP's original post: "They are notoriously difficult to remove, both for the tight access and the inhuman force required to remove them."

 

[sberry]

Got an 8 mm,,, how hard can it be? I do them with a Walmart set.

 

[Shaners256]

Got an 8 mm,,, how hard can it be? I do them with a Walmart set.

What year A4?

I have a B5 A4 that I have removed the rear caliper brackets many times. I doubt they changed too much even with the newer models.

I just use an 8mm hex socket, mine is 3/8" drive, with a short 3" extension. The extension is required to get the drive end past the stabilizer link that is in the way. The ratchet would hit the stabilizer link as you remove the screw, but the smaller diameter of the extension allows you to get past the stabilizer link.

 

[danski0224]

Can HF cut off discs be used on Snap On tools?

 

[bmwpowere36m3]

Don't over-think it... you got the bit already. Cut it and use it. Seems crazy, but the # of good tools we've bent, ground or re-worked is a bit sad. At he end of the day it's got a job to do. Usually the tool is the least expensive part of the whole equation.

 

[gdocktor3]

I recently picked these up. They're cheap and strong. http://www.tooldiscounter.com/ItemD...u7rqRjSLd8XIh8qabO20KiaAtapHhsOKF4aAmWS8P8HAQ

 

[toolslut6.0]

Ive cut down a bunch of mac usa allen sockets meyric and standard. Just cut the off with cut off wheel dont worry so much about heat just drive the bit out and flip it so the factory end is being used to drive the bolt

 

[nbpt100]

Every Idea I have read on here will work with the exception of the use of the hack saw or band saw to cut the hex bit. Use what you have and don't worry too much. More than 9 ways to skin this cat.

 

[SuzukiGS750EZ]

I HATE THOSE! I want to say i modified an allen key and used a jack handle for leverage. Those things are horrible. The first time i came across one i thought to myself "What jackass decided to do this!?". I'd still like to know...

 

[nbpt100]

I HATE THOSE! I want to say i modified an allen key and used a jack handle for leverage. Those things are horrible. The first time i came across one i thought to myself "What jackass decided to do this!?". I'd still like to know...

Socket head cap bolts are pretty are relatively common on brake calipers and brackets. The Germain car manufacturers seems to really like them.

Look on the bright side, it is better than a Torx bolt which are also sometimes used.

 

[SuzukiGS750EZ]

The a4 calipers are the ones which the bolt is facing inward underneath the bracket that's on the underside if the car, right? If I explained that right lol. Not enough room for a ratchet let alone a full size Allen key. Or am I thinking of another audi?

 

[DPDISXR4Ti]

OP, why are you removing the bracket?

For this application, to replace the rotor, the bracket needs to come off.