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How to Cut Bolts Without Damaging the Thread

Thread damage commonly occurs when cutting bolts, making the bolts difficult to start in a nut or threaded hole. Bolts made of certain materials, such as stainless alloys, will have a tendency to gall and bind if the bolt threads are damaged during cutting operations. Preserve the shape and pitch of the threads -- particularly the starter thread -- to prevent the bolt from binding in the hole. Maintain the threads during cutting by using proper techniques and tools.

Instructions

1

Install a die of the proper diameter and pitch on the bolt to be cut. Thread the die all the way down to the bolt head or shoulder.

2

Install a nut of the proper diameter and pitch onto the bolt. Thread the nut down the bolt until the bottom edge of the nut is on the desired cut location.

3

Grasp the bolt firmly above the nut and brace your hand against a firm surface to hold the bolt steady for cutting. Cut the bolt off, using a hacksaw. Use the bottom edge of the nut as a guide to make certain the cut stays square and perpendicular to the bolt.

4

Remove the nut from the bolt.

5

Grind a 45-degree chamfer on the cut end of the bolt to remove any spurs from the starter thread, using a grinder. Do not grind the chamfer beyond the first thread.

6

Rotate the die off the bolt to clean up any remaining spurs and make certain the threads are correctly shaped.

7

Remove loose metal shavings from the bolt, using a chip brush.