A breaker bar allows you to extend the overall length of a wrench or socket wrench so that you can apply greater force to the bolt without putting any more pressure on the wrench.
Step 1 – Determine The Length
The length of the breaker bar will determine whether it will work properly. The longer the breaker bar, the more force you can exert on a nut or bolt without putting any more physical pressure on the bar. When considering the length, however, you must also consider how much space you have to work with. The most common sizes are 12 inches, 24 inches and 36 inches but you can make a shorter or longer breaker bar.
Step 2 – Find the Right Bar
A breaker bar must have the right internal diameter to fit around your wrench. You want it to be snug enough where it will not wobble but be able to attach it to the end of the wrench or socket wrench with ease.
It must be made of a strong material that will not bend, warp or snap. Galvanized steel pipes are ideal for this application as they are extremely strong and relatively inexpensive.
Step 3 – Measure Out the Size
Measure the length of the wrench you will be using with the breaker bar. Then measure how far the wrench goes into the pole you are using.
Measure up to the length you want the breaker bar to extend beyond the wrench, and then add the length of wrench that will be inside of the breaker bar. This number can be figured out by subtracting the exposed length of the wrench when inserted in the pole from the total length of the wrench or socket wrench. Make a mark on the pole using a permanent marker.
Step 4 – Cut the Pole
Use your hacksaw to cut the pole on the mark you made. Make sure you cut straight so the pole does not have a crooked edge. Having a crooked edge could lead to rocking that would reduce the effectiveness of the bar.
Step 5 – Sand the Pole
Apply rough grade sandpaper to the cut edge of the pole to remove sharp or rough metal.
Finally, use the medium grade sandpaper to sand the end of the pole down until it is smooth. You can use a belt or rotary sander to achieve a smoother finish, but this is not necessary.