ETLB Squawk Forums — Archive

Those of us who fly behind Rotax engines know how difficult it is to remove the four socket head cap screws holding the recoil starter in place using an Allen wrench. The space between the starter cover and firewall is very limited making it difficult to turn the wrench once you get a wrench in there. Additionally, the long end of the wrench is engaged in the screw, leaving only the short end for applying torque.

My solution was to make a "handle" for the Allen wrench. Another solution is to replace the socket head cap screws with hex head bolts, but beware, not all sockets will fit over the bolt head and still clear the recoil's cover.

If you don't use this tip in this application, you may find another use for it. For me, it goes in my toolbox.

First, layout a circle equal in radius to the Allen Wrench's offset on a piece of wood. Drill a hole the a bit smaller than the wrench size. Make a groove radiating from the center and as wide and deep as the wrench is thick. I used a chisel but other methods will produce the same results.

Second, cut the circular layout using a hole saw, fly cutter, scroll saw, or chain saw. Whatever works for you.

Third, a little wood burning provides "grip" and adds some character to the handle.

To use, press the Allen wrench into the hole and groove. Then like Chubby Checker sang: "Twist Away." (us older guys will get this)

you can buy a little T handle Ratchet that is 90 degree geared.  Very compact.
Also, T Handle Allens are common.

Thanks for that information Ace, I was unaware. The ratchet sounds ideal as it would provide faster rotational motion than what I created. Where were you when I needed that information?

Here are some photos of using that Allen handled wrench in the tight space between the recoil starter and the firewall. I could only show three of the four screw locations as the fourth one was completely hidden from view. I will try to post them in my original post. Well that didn't work either. I guess there just will be no photos.