Ever found yourself wrestling with a stubborn car fuse, those tiny protectors of your vehicle’s electrical system? It’s a common frustration. Just yesterday, while replacing the cigar lighter fuse on my ‘2015 Transit, what should have been a simple task turned into a mini-battle. That’s when the idea sparked: why not create a simple Car Fuse Removal Tool to keep in the vehicle for future needs?
While you can buy dedicated fuse pullers, sometimes a DIY approach is quicker and more satisfying. Plus, making your own car fuse removal tool ensures you have one on hand whenever you need it, especially for those unexpected roadside repairs. This guide shows you how to craft a basic yet effective tool from readily available materials.
Why Make a Car Fuse Removal Tool?
Car fuses are designed to protect your car’s circuits from overloads, and they do their job well. However, their snug fit in the fuse box can make them incredibly difficult to remove by hand. Fingers can be too clumsy, and using pliers or screwdrivers risks damaging the fuse or surrounding components. A dedicated car fuse removal tool, also known as a fuse puller, is designed to grip these small fuses securely and allow for easy, damage-free removal. Having a car fuse removal tool in your glove compartment is a small investment in time that can save you a lot of hassle later.
Crafting Your Own Car Fuse Removal Tool: A Step-by-Step Guide
This DIY car fuse removal tool is surprisingly simple to make using basic tools and materials you might already have. It’s based on a spring steel design for durability and effective fuse gripping.
Materials You’ll Need:
- Spring Steel Wire: About 6 inches long, 1/8 inch wide, and 1/16 inch thick. A piece of wire from an old fish tape spool is ideal due to its stiffness and rust resistance.
- Plumbers Torch: For heating the steel.
- Vise: To securely clamp the steel.
- Hammer: For shaping the tool tips.
- File: For flattening the tool ends.
- Grinder (Optional): To refine the tool tips.
Step-by-Step Instructions:
- Shape the Basic Form: Heat the middle section of your spring steel wire with the plumbers torch until it’s pliable. Bend it into a U-shape, ensuring the tips are approximately 1/2 to 5/8 inches apart. This width is ideal for most standard car fuses.
- Soften the Tips: Heat the ends of the U-shaped wire to a glowing red color. This process removes the temper from the steel at the tips, making them easier to shape in the next steps. Allow the heated ends to cool down slowly at room temperature; do not quench them in water.
- Flatten the Ends: Use a file to flatten the tips of the wire. This creates a better surface for forming the fuse-gripping lips.
- Create the Gripping Lip (Side 1): Securely clamp one side of the U-shaped wire vertically in a vise, with about 1/8 inch of the tip exposed above the vise jaws. Using a hammer, gently peen the exposed tip to create a small, inward-facing lip. The goal is a very slight lip, around .05 inches or so, angled inwards at approximately 60 degrees. This lip is crucial for securely grabbing the fuse.
- Create the Gripping Lip (Side 2): Repeat step 4 for the other side of the U-shape to create a matching inward-facing lip. Ensure the lips are aligned to effectively grip the fuse from both sides.
- Refine the Tips (Optional): For a more refined finish, use a grinder to angle the backs and sides of the tips as shown in the images. This step is mainly for aesthetics and can improve access in tight fuse boxes, but the tool will function effectively without it.
Finding the Right Replacement Fuse
Once you’ve successfully removed the faulty fuse with your new car fuse removal tool, you’ll need a replacement. As I discovered, not all fuses are created equal. Specifically, LittleFuse JCase fuses may not be compatible with all vehicles, even if they appear to be the correct type. It’s always best to double-check your vehicle’s manual for the correct fuse type and amperage.
For my Transit, a trip to the Ford dealership was necessary to get the exact replacement. Sometimes, going directly to the dealer’s parts department, especially for specialized components like fuses, can save you time and ensure compatibility. Simply presenting the old fuse to the parts specialist can often lead to a quick and accurate replacement.
A Simple Tool for Peace of Mind
While this DIY car fuse removal tool might not be patent-worthy, it’s a practical solution to a common car maintenance annoyance. Keeping this simple tool in your car means you’ll be prepared to tackle fuse replacements with ease, wherever you are. No more struggling with slippery fuses – just a simple, effective tool you made yourself.
