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Old 03-16-2017, 03:43 PM
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Default Need to cut 150 bolts.

I need to trim off about 1/2" from 150 1/4-20 bolts. I could use a cut off wheel, but then it gets an acorn nut on the end. I have a pair of cutters for small machine screws that leaves a burr free end. Is there any sort of tool that will cut 1/4-20 without a burr?
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Old 03-16-2017, 03:46 PM
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Put the nut on before you cut.....when you back it off, the burr is gone.
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Old 03-16-2017, 04:01 PM
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Put this jig in a vice and use a cut off wheel, impact in and out
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Old 03-16-2017, 04:10 PM
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I routinely cut the heads off 1/4-20 x 3" screws a box/100 at a time. I use them as studs so both ends need to be nice.

I'll horizontally clamp 2 screws at a time on the threads in a vise, heads sticking out. The jaws have aluminum inserts (a couple pieces of angle cut to length) so I don't mar the threads. I use a sawzall with a finer-tooth blade (18TPI?) angled ever so slightly against the head of the screw.

After the screws are cut I remove from vise, put in a small box and keep the cut ends on the same side of the box. Then repeat 50 times... Takes me about 10-15 minutes to do the box.

Once the studs are all cut, I'll chuck them into a cordless drill set on low speed and while turning in the drill, I'll start sanding the edges on a horizontal sanding belt. I start on a 45 then while sanding I'll tilt the drill up to vertical to sand the end of the stud. I'd say I sand each stud less than 5 seconds.

Then while the stud is still in the drill I'll move to the running deburr wheel and repeat the action. Then unchuck the stud and move to the next one. I keep the cut ends oriented the same because the cut end goes "in" in my application.

I don't happen to have any pictures handy but the whole process takes me less than an hour...
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Old 03-16-2017, 04:16 PM
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Quote:
Originally Posted by Walker View Post
I need to trim off about 1/2" from 150 1/4-20 bolts. I could use a cut off wheel, but then it gets an acorn nut on the end. I have a pair of cutters for small machine screws that leaves a burr free end. Is there any sort of tool that will cut 1/4-20 without a burr?
Andy, for that many bolts, I would make shear similar to those cutters.
cut two rounds off a piece of 3" shafting about 1/2" thick, this will be the depth gauge for the cutoff parts.
Face them off smooth in the lathe. Stack them up with the faced sides together, drill a 3/8" hole through both of them about 1/2" from the edge. That's your pivot hinge.
Now drill another 7/32"hole about center and thread one of the rounds to 1/4" and drill the other hole out to 1/4" or larger. Weld a handle on this round and something to grab in the vice onto the threaded round.
Yer done.
I would use some cold rolled or T&G stock so the shearing edge will last and make sure to keep the pivot bolt snug so there is no play.

You actually could thread 2-3 holes in that plate so you could clip 3 bolt with one throw of the lever.

It's just a glorified rebar shear.
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Old 03-16-2017, 04:46 PM
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You can't buy shorter bolts?..
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Old 03-16-2017, 06:50 PM
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Not great for your application but here is a neat idea I copied from a magazine a while back. Hopefully it will help someone.
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Old 03-16-2017, 08:30 PM
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I like that strap hinge idea, I usually cut bolts on my vertical band saw but tricky to keep them from slamming downwards, gotta hold them real good. That strap hinge idea would hold them great. No need to fix threads when you cut them with a band saw.
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Old 03-16-2017, 09:20 PM
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I should have explained a wee bit better. These are swage studs on cable railing. The cables are in and tensioner. I just need to nip off the ends and install the acorn nut. I was just hoping for a tool to chop them off quickly and accurately.
I don't really want to put a nut on then back it off, just from a time perspective. I wouldn't mind cutting it with bolts cutters and impacting on the acorn nut, but I don't have clearance to get and impact driver in there, only have 2 1/2" clearance to the wall.
I think a sawzall and a fine blade is what I will end up using, just don't like it.
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Old 03-16-2017, 09:48 PM
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I would put them in a drill and shorten and bevel them using a belt grinder. When ever you bevel threads on a belt or wheel grinder hold the bolt vertical to the belt or wheel to insure the nut will start easily.
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