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Slavia · Moderator

My favorite way to shorten screws is to chuck them in a portable drill. Then, I cut into them with a Dremel and abrasive cutoff wheel, using the chuck jaws as a guide.

This cuts the screw pretty square, but leaves a sharp edge. Holding the Dremel at an angle and just "kissing" the edge creates a smoother bevel.

If the Dremel leaves a finish that is not as smooth as desired, the spinning screw end can be held against a piece of abrasive cloth. This technique works well for shaping screw heads, also.

yourdaddyjoe · Supporting Member

I have a set of HD wire crimpers that has the ability to cut the most popular small size screws... If done right... the leaves the threads nice and clean... The key is to insert the screws in the threaded side so when you back it out... it straightens the cut end of the threads. It will leave the end sharp.

If you want to dress the end... Clean it up like Slavia said with the drill and abrasive paper...

It will cut the following sizes:
4-40
6-32
8-32 (Most Common Crosman screws)
10-32
10-24

Slavia · Moderator

I like the Dremel method because it's easier to cut a perpendicular end, and because you can bevel the end slightly to remove sharp edges. This is a plus when starting the screw in softer metals like aluminum, zinc (pot metal), or brass.

It's also useful for shaping the screw head to fit a counterbore or countersink. Sometimes you just don't have room for a (large) standard size head. Or if you want to change a flathead to an oval head. Or a button head to a square oval head - stuff like that.

yourdaddyjoe · Supporting Member

Good point...

(Yes... pun intended Mr. Green

)

Slavia · Moderator

I also use steel "tee" nuts and brass thumb nuts a lot. They make good threaded inserts, threaded spacers, etc. I sacrifice a screw by cutting off the head, and use it as a mandrel to hold the nut in the drill.

Like the screw cups on my G1:
http://www.airgunhome.com/agforum/viewtopic.php?t=1760&postdays=0&postorder=asc&start=90

And the Hakim sling swivel:
http://www.airgunhome.com/agforum/viewtopic.php?t=1253&start=45

I'm jealous of you guys with lathes.

yourdaddyjoe · Supporting Member

Nice...

I have a red dot sight that the locking nut stripped... The stud is a odd ball size thread that I can not find at my local hardware store...

I am going to have to spin a new nut and thread it...

Alstone · Moderator & Site Supporter

This is a method I use to shorten threads, get a piece of 1/8 steel plate about 1" wide, drill and tap a series of holes of the most popular size you use in a line, cut a slot right down the middle and drill a large hole at one end.

To cut a screw down screw it in the correct thread to the length required, nip the plate up in a vice and saw off the screw, you can then screw it in a bit further and clean up with a file.

Job done.

Al