Author Topic: How to shorten bolts the OCD way  (Read 2712 times)

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Offline martin99

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How to shorten bolts the OCD way
« on: January 09, 2015, 04:22:45 pm »
Hi fellas. Shortening bolts. Easy right? Just get a hacksaw, hold it in the vice and saw away. Although sometimes the length is critical, or you have a cheesehead that won't stay put in the vice, or you are trying to cut through a hard material like stainless and the blade is skipping across the threads and buggering them up. ::)

You engineering types will know this, but for the more technically challenged or OCD types like myself, here's how I was taught to shorten bolts many years ago. Particularly handy if you need to shorten several to the same length.

First, select your patient.

Wind a die down the thread to the amount you want to remove

Hold the die in the vice - not too tight, but enough to nip up the die and hold the bolt tight

Keep the blade flat against the die as you cut, using it as your guide

Turn the die down a couple of threads and reposition it in the vice,again nipping it up to hold the bolt secure

Use a flat file to clean up the cut, hold it at 45 degrees to remove the burrs

Surgery completed!

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Offline Don R

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Re: How to shorten bolts the OCD way
« Reply #1 on: April 04, 2015, 09:09:32 pm »
 Or you can saw through a nut on one side, thread it onto the bolt then the vise will pinch it tightly while you cut.
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Offline FunJimmy

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Re: How to shorten bolts the OCD way
« Reply #2 on: April 04, 2015, 09:51:53 pm »
Nice tip. Thanks
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Offline 754

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Re: How to shorten bolts the OCD way
« Reply #3 on: April 05, 2015, 10:26:11 am »
If you do them often tap a piece  of Flat bar with sizes you need. Then stick them thru and cut with zip disc, it will deburr as you thread it out...then go to grinder or sander and bevel slightly..
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Offline BobbyR

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Re: How to shorten bolts the OCD way
« Reply #4 on: April 05, 2015, 11:44:09 am »
All great ideas. In a pinch a nut will do the same job.
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Offline HondaMan

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Re: How to shorten bolts the OCD way
« Reply #5 on: July 02, 2015, 07:06:14 pm »
Nice job!
Now I will probably cuss while I do this to my next ones, knowing it will look far better than the way I've been doing them...and I won't be able to "go back" to the old way anymore!
;) :( :D
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Offline mystic_1

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Re: How to shorten bolts the OCD way
« Reply #6 on: July 02, 2015, 07:14:42 pm »
Huh, never thought of using a die for this, I always used a nut, but a die is a great idea because the hardened steel would make an excellent guide for the saw blade and wouldn't get damaged in the process.  Hex dies would be particularly good for this.

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