Bottle Cap Removal Tool

We recently began buying sugar free ginger ale in a glass bottle with a twist off cap. Somehow these particular bottles are more of a challenge for removing the cap. I made a similar tool for an invalid who has very little dexterity in his hands so he could open 2 liter bottles by himself and decided to make one for us, too.

Tools

1. 4 inch angle grinder and cutting disc
2. Measuring tools
3. Hammer
4. Metal cutting bandsaw
5. MIG welder
6. Vise
7. Magnetic holder for welding
8. Aluminum angle
9. Spring clamp
10. file
11. Hole punch
12. Drill with 1/8 inch bit

Materials

1. 20 gauge sheet steel
2. 1/8 inch steel rod
3. 1/8 x 1/2 inch flat bar
4. 1/8 x 1 inch flat bar

The cap on these bottles is almost 1 3/16 inches in diameter (30mm). That is a little larger than similar twist off caps we have seen. It also seems to require more force than most to loosen.

Cut a strip of 20 gauge sheet steel 3/4 inch (19mm) wide. I cut it to a 3 3/4 inch length (95mm). That will allow about a 3/16 inch gap between the ends.

I used a piece of pipe nearly the same outer diameter as the bottle cap to form a round collar with a gap where the ends meet.

The two ends of the collar need to be connected without affecting the 3/16 inch (4mm) opening. I cut a piece of 20 gauge sheet steel to fit the outer surface of the collar. I used a vise and a magnetic holder for welding to hold the pieces in position for welding. Unfortunately, some weld bead rolled over into the space to be occupied by the bottle cap. I used a file to remove as much as possible. Grind smooth, if needed.

I cut a piece of 1/8 x 1/2 inch flat bar about 6 inches long and bent about 3/8 inch over on one end to make a right angle. Grind a blunt pointed edge onto the bent portion.

I used a spring clamp to hold the handle under a piece of aluminum and laid a piece of 1/8 inch rod one inch in length onto it. This will be the axle about which the handle lever turns.

The bottle cap has a portion below where it separates that does not come off. To allow for that, I did not center the rod on the flat bar, but set it offside. Weld the rod to the flat bar.

Mark for a hole to be drilled in the piece that joins the ends of the collar and drill. When the axle is in the hole, the pointed end should fit easily in the collar opening. Position accordingly before punching to mark the location of the hole.

Cut a piece of 1/8 x 1 inch flat bar to a length of 1 7/8 inches (45mm). Drill a 1/8 inch hole in one corner. Loosely assemble so the axle is in both the lower and the upper holes and the lever moves smoothly. Weld at three or so points where the edge of the collar aligns with the edge of the 1/8 x 1 inch flat bar. Grind away sharp edges and corners. You may want to add spacer material to keep the bluntly sharpened end aligned with the upper portion of the bottle cap.

Slide the tool over the bottle cap. Grasp the bottle with one hand. Pull on the lever with the other. Though this is sized for a slightly larger diameter than usual cap, it works well on the regular sized caps, too.