Short Answer
Introduction to Hardware Modification
In many DIY and engineering projects, a specific fastener may be required that is not readily available in a local hardware store. One common modification is the conversion of a hex socket head bolt into a grub screw (also known as a set screw). This process allows a machinist or hobbyist to create a low-profile fastener that can sit flush or beneath the surface of a material.
Understanding the Components
Before beginning the modification, it is essential to understand the difference between the two components:
- Hex Socket Head Bolt: A fastener with a cylindrical head and an internal hexagonal drive, designed to be tightened with an Allen key.
- Grub Screw: A threaded fastener with no external head, typically designed to be driven entirely into a hole to put pressure against another part.
The Modification Process
The most efficient way to perform this conversion in a home workshop or small machine shop is by using an angle grinder. This tool provides the abrasive power necessary to remove the head of the bolt quickly.
Step-by-Step Execution
- Securing the Workpiece: To ensure safety and precision, the hex bolt should be firmly clamped in a vice. This prevents the bolt from spinning or flying off during the grinding process.
- Cutting the Head: Using a cutting disc on the angle grinder, carefully slice through the head of the bolt. The goal is to remove the entire hexagonal top, leaving only the threaded shaft.
- Facing and Leveling: Once the bulk of the head is removed, the end of the bolt may be uneven. Use the grinder to perform a “facing” operation, grinding the top surface flat and perpendicular to the threads.
- Finishing: Depending on the application, a small amount of sanding or filing may be required to remove burrs and ensure the grub screw fits perfectly into its intended bore.
Tooling and Equipment
| Tool | Purpose |
|---|---|
| Angle Grinder | Primary cutting and facing of the bolt head |
| Bench Vice | Stabilizing the workpiece for safety |
| Safety Goggles | Protection against high-velocity metal sparks |
| Metal File | Fine-tuning the finish and removing burrs |
Safety Considerations
Warning: Metalworking with angle grinders generates significant heat and sparks. Always wear appropriate Personal Protective Equipment (PPE), including safety glasses and gloves, and ensure your workspace is clear of flammable materials.
Applications in Engineering
This DIY technique is particularly useful in model engineering, jewelry making, and general home improvement. By converting existing stock, users can avoid the cost of specialized fasteners and reduce project downtime. While a professional lathe could achieve a more precise finish, the angle grinder method is a “cheap and perfect” alternative for most practical applications.
FAQ
Can I use a hacksaw instead of an angle grinder?
Yes, a hacksaw can be used, but it will take significantly more time and effort than an angle grinder.
Will this damage the threads of the bolt?
As long as you only cut the head and do not grind into the shaft, the threads will remain intact.
Is this method suitable for stainless steel?
Yes, but ensure you use a cutting disc specifically rated for stainless steel to avoid premature wear.
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