heat exchanger barrel nuts - can't get at them
 

Fellas - I can't remove two barrel nuts on one of my heat exchangers as the access holes don't line up with the nuts. I've tried grinding down the shaft of the 8mm hex tool in order to skinny it up and give me more play... but the mis-alignment is too great.

Any suggestions?

Barrel nuts.........
 

Sears sells a set of hex adapters that are in 1/4", 3.8" and 1/2" sizes. You could put one of these (probably in the 3/8" size) into an 8mm hex socket and have room to turn it with an open end wrench. Or, if the old heat exchangers are not to be reused, simply cut them off with a sawzall. Or, drill a hole that will align with the barrel nut and have at it! Hope this helps.

I've used a short piece cut off an Allen wrench, turned with an open end wrench. If you can get a Gear Wrench on it, even better.

I had a stripped nut once and got it by using a small pair of channel locks, with a larger pair of channel locks to grab the handle of the small pair.
You go over the top of the heat exchanger with this method, of course.

Good luck.

I can't see how it can be unaccessible. It had to go on somehow.

got them!
 

Thanks guys for the suggestions.

I ended up taking a big 8mm alley key and straightening it out with heat and a hammer. I was then able to get enough bite on the nuts (through the holes in the exchanger) while turning with a crescent wrench.

Hopefully, when they go back on I won't have to fight with them like I did.

Thanks again.

SSi's or OE HE's? ...I noticed the same alignment issue with my SSi's (fwiw)

OE Heat Exchangers

Harbor Freight has a very inexpensive set of Metric long allen sockets. I think I paid 15 dollars. Worked like a champ.

Don't forget to use the copper never seize when reassembling.

I've never had a problem with any OE heat exchanges (SC or Carrera) where the holes in the sheet metal didn't line up with the barrels, and I've removed quite a few over the past few decades. Wonder if someone put barrels on studs that were supposed to have regular nuts at some point.

FWIW, you might try the ball headed allens next time. They don't have quite as much surface area inside the barrel but they allow up to about 15 or 20 degrees of misalignment and still engage in the allen.

206EFABLM, Set, Socket Driver, Metric, Ball Hex, Long, 4 to 10 mm (6 pcs.)

[QUOTE=island911; ...I noticed the same alignment issue with my SSi's (fwiw)[/QUOTE]

That would be the last thing I need...

Snap 3 studs, had to do one Time-Sert