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The hardest thing about it that I could think of would be finding a bolt that would thread into the hanger. I've searched for them for a project and they are so rare that only one online store stocked them. You could use a derailleur bolt like pictured below, but it'd be hard to attach to an arm and still be able to turn.

Image


Another thing that just crossed my mind would be using an old derailleur body (taking off the cage and spring system) and finding a way to attach a long arm to the threaded portion. You'd just use the 5mm hex key to thread it into your hanger. Just my .02
 
How about using a 10 or 12" adjustable wrench with a zip tie (or something) as a feeler/distance measurement tool? Then you don't have to worry about finding something to thread into the hanger. Wouldn't be as nice as being able to rotate the thing but seems like it would get you pretty darn close in terms of alignment.
 
The hardest thing about it that I could think of would be finding a bolt that would thread into the hanger. I've searched for them for a project and they are so rare that only one online store stocked them. You could use a derailleur bolt like pictured below, but it'd be hard to attach to an arm and still be able to turn.
A front axle has the same pitch in many cases. You might even be able to thread the front axle into the derailleur bolt hole while mounted to the wheel. You can then use the wheel as leverage to tweak the hanger and when the 2 are parallel, you should be good to go. I think the pitch is 10x1. I was able to find a few at a local auto supplier but it wasn't easy to find. Taps and dies in this size/pitch are pretty common however.

Good luck.
 
I've also used the Park tool, and had the same thought about DIY'ing one - it's a pretty straightforward design. Still, after thinking about it for a while, I came to the conclusion that for as much time & trouble it'd take to make one that worked as well, the price of the Park tool IMHO was a bargain. Sure, it's not exactly cheap, but it's not a couple hundred dollars, either.

Even so, as often as I need to use one, I don't own one.
 
All you need to do is trace the outline of your derailleur hanger and right hand dropout onto a piece of cardboard, mirror image it and tape it to the left hand dropout so that the derailleur mounting hole is directly opposite the cutout's derailleur mounting hole. With it so far? Now screw a 10 * 1mm axle, 174mm (full length threading for track nuts) and use it as a lever to bend the hanger until it points straight at the correct spot on the left hand dropout.

Clear as mud? I just got a DAG.

- Joel
 
All you need to do is trace the outline of your derailleur hanger and right hand dropout onto a piece of cardboard, mirror image it and tape it to the left hand dropout so that the derailleur mounting hole is directly opposite the cutout's derailleur mounting hole. With it so far? Now screw a 10 * 1mm axle, 174mm (full length threading for track nuts) and use it as a lever to bend the hanger until it points straight at the correct spot on the left hand dropout.

Clear as mud? I just got a DAG.

- Joel
That is pretty ingenious! The key would be to tape the cutout precisely to the left dropout.
 
I think even easier would be to get a square angle at the inside left drop-out to help align the plain axle you screw into the hanger. Once the axle is square with the drop-out, it's pretty much it. Unless the hanger has to be twisted too...
 
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