Another thing inspired by my recent bike mechanics' training seminars put on by the Pro bicycle mechanics association. (PBMA)
DT Swiss showed us how to maintain their awesome hubs, and several of the tools we used looked to be completely printable, so I drew them up, printed them out when I got home, brought them in and tested them the next day. They worked perfectly!
The one tool that can't be printed
In the photo of the original DT Swiss maintenance tools, all of the silver aluminum pieces can be printed. The one black tool is a steel tool which is used for removing the drive ring from the rear hub body, and this is made from hardened steel. This is mounted in a strong vise on a heavy bench and then can take as many as three people turning the wheel to break the ring free. We were told if the tool wasn't clamped into the vise properly, it could break from the stresses applied to it. Considering a hardened steel tool could break in this situation, I didn't even bother trying to make one that could be 3D printed. This tool can be purchased from Amazon or Worldwide Cyclery as well as any shop that carries DT Swiss parts. It's only needed if you need to replace the bearing pressed into the hub shell on the drive side which is behind the ring nut, but it's also the only way to get that bearing out without damaging it or the hub.
There are four tools here:
- Axle protector
This is inserted in the end of the thru-axle in the rear hub and used to hammer out the non-drive side bearing. This prevents the hammer from marring or deforming the thin aluminum axle.
- Seal driver
There is a thin seal which fits between the freehub body and the drive ring. When the drive ring is unscrewed (see above) it will push this seal out, but to reinstall it, you need this tool. The thin lip holds the seal and drives against the metal shell so it doesn't damage the rubber seal lip. You can see the seal installed on this tool in the first photo.
- 6802 press
This is a pretty generic bearing press for 6802 bearings. The flats are for easily mounting it into a vise.
- 6902 press
Same as above, use whichever one your hub requires. You will likely need two.
I printed these test parts in PLA and didn't use a solid infill, and they worked okay, but the demonstration hubs have had bearings pressed in and out repeatedly, so the bearings came out pretty easily. If you were to print these for use on real hubs that have been ridden, you'll probably want to use more shells at the least, and 100% infill wouldn't be a bad idea.