Curiosity got the best of me so I went down to the shop to take some actual 
measurements.  The opening on the FR-6 is 15.29mm; the PW axle cap diameter 
is 18.87mm.  So milling out the tool to about 19mm may not involve removing 
as critical an amount of material as I feared.  I think I might go after 
this solution.  BTW, from what little I know about machinist work, I'm 
thinking this would probably get done with a vertical milling machine, not 
a lathe.

Thanks all for your suggestions.

On Tuesday, November 17, 2015 at 8:07:05 PM UTC-6, George Schick wrote:
>
> Will - your advice is exactly how i do it.  Then, since the axle cap can't 
> be reinstalled with the BMX tool in there, I shore it up with a couple of 
> fender washers to support it on the DS.  I have also thought about your 
> suggestion to bore out the hole on the FR-6 tool to fit over the axle cap 
> (I have a machinist friend with the lathe), but I fear that it may leave 
> the remaining metal too thin to withstand the torque involved in removing 
> the freewheel.  Might be worth a shot sometime, though.  They're not that 
> expensive a tool…
>
>
> On Tuesday, November 17, 2015 at 7:57:18 PM UTC-6, William deRosset wrote:
>>
>> Dear George,
>>
>> Can you pull the DS and leave the NDS (my non-track end-cap-swappable 
>> Phil hubs are in VT these days, or I'd check) in place to locate the QR? 
>> All the QR needs is to provide some preload to hold the splines 
>> prongs/splines in place until the freewheel shifts a bit. Alternatively, 
>> you could throw your freewheel remover on the lathe and bore it out a 
>> bit....
>>
>> Best,
>>
>> Will
>> William M. deRosset
>> Fort Collins, CO
>>
>> On Tuesday, November 17, 2015 at 5:32:08 PM UTC-7, George Schick wrote:
>>>
>>> Anyone out there know of a "BMX" freewheel removal tool that will work 
>>> well with a Phil Hub?  Unfortunately, the center hole on a commonly used 
>>> tool, like the Park FR-6, is not large enough to slip over the 
>>> larger-than-normal axle caps of the Phil hub.  This means that the axle cap 
>>> on the drive side must first be removed, which is not only an extra PITA, 
>>> but then the removal tool has to sit against the notches on the freewheel 
>>> without benefit of the QR skewer to hold it in place, risking the stripping 
>>> of the FW notches in the process.
>>>
>>>
>>>

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