Just did the pulley swap in about 4 hours, without either of the 'special' tools: no pulley puller, and no tensioner bar.

I can't say I would recommend it, especially if you're able to borrow the proper tools. BUT it IS possible, if you're on a tight budget, to do the job without.

Aside from the tools, I followed this fantastic video by Mod Mini, which shows everything involved in the job:


*** TENSIONER BAR SUBSTITUTE ***

9/16" or 16mm socket over the tensioner bolt head. This will act as the fulcrum point for the lever. If it's wobbly, shim the inside of the socket with a bit of soda can to get it tighter. There will be a lot of leverage on it.

Slide a bolt into the hole in the tensioner arm (largest size that fits - I used a 1/4-20). Longer the better - you don't want this popping out under leverage.

Some long lever (I used a 2ft wood clamp). Use the socket and the bolt and pull down hard on the end of your lever to move the tensioner up. Have a friend pop the allen key into the hole as described in the video. Don't put your fingers in there, in case the socket or lever slips!

 

The do-it-self belt tensioner tool is a great idea. Cutting the pulley off, lets just say I am glad you are not my dentist.

 

I would never want to put myself, and especially the poor Mini, thru with that grinding job. It is much easier to buy a puller, use once, and sell it for $15 less. Even with the purpose-made puller, the pulley did not come out without fighting.

 

+1

I like the Belt Tensioner tool, seems like it is more stable than the actual unit.