Diy Sleeve Removal Tool For Post-Millennium Groupheads

Removing sleeves from post-millennium La Pavoni lever machines does not require an expensive factory tool. With a simple piece of steel and the correct dimensions, you can build a reliable sleeve removal tool yourself in just a few minutes.

This guide explains the concept, the critical measurements, and the design considerations that make the tool safe and effective.

Why You Don’t Need the Official Tool

An original removal tool is available for purchase, but the task itself is mechanically simple. Unlike older shower screen systems that may require more specialized solutions, sleeve removal only requires two things:

• A solid bar that spans securely from socket to socket
• Enough leverage to break loose a seized sleeve

Nothing more sophisticated is necessary.

Material and Thickness

A steel bar with a thickness of 5 mm is ideal. It provides sufficient strength without unnecessary bulk.

The tool shown here was made from scrap metal. The overall design is flexible — you can weld a permanent handle or keep it compact and use an extension pipe when additional leverage is needed.

Critical Dimension: Width

The most important measurement is the width of the engaging section.

• Recommended width: 53 mm
• Group head opening: approximately 50 mm

The slight excess prevents the tool from slipping under load. If the tool is exactly 50 mm wide, it may slide off — especially if the sleeve is tightly seized from heat and long-term use.

At the same time, it must not be too wide, or it will not fit into the group head. Around 53 mm is an effective compromise.

Engagement Depth

You do not need excessive depth. Approximately 20 mm (2 cm) of engagement is more than sufficient to achieve a stable grip.

The goal is controlled force, not brute overengineering.

Design Flexibility

You can:

• Keep the tool short for easy storage
• Add a removable extension for leverage
• Weld a fixed central handle for rigidity

The exact configuration is up to you. Precision in width matters more than aesthetics.

Upgrade Opportunity

This tool allows you to remove plastic sleeves and replace them with brass or steel alternatives, improving durability and long-term performance.

Final Thoughts

This is a simple, virtually zero-cost solution built from scrap metal. With correct measurements and sensible use of leverage, it performs the same function as commercial tools at a fraction of the cost.

Practical, effective, and easy to build — exactly what a workshop tool should be.