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I used a lathe, (I
finally broke down and bought one) but, with the exception of the drilling
template, this could be done with a drill press and grinder, . The only
real advantage to this method is that you don't have a bottom nut with a
hole it, if that matters to you. |
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For
a better look, click on images to enlarge. |
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In
this variation, the bolt heads cannot be drilled from behind, so a template
is needed to keep the drill bit from wandering. I used a discarded hex head
from a grade 8, 1" bolt. I cut a shoulder about 3/16" deep, then dished
it out so it would fit the contour of the carriage bolt. The carriage bolt in
the vise is ready to drill. |
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This
shows the shorter 1/2" carriage
bolt after the square shoulder has been removed and the shank turned to
1/4". The head has been cut thinner and the cap filed free of grade
markings and galvanizing. A parting tool is ready to cut it free.
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I
flipped the template over onto the carriage bolt head, then drilled the first
hole. I put a pin in the drilled hole (red arrow) to keep everything in line,
then drilled the second hole. |
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I
clamped the spanner bolt wrench upside down in a vise, then placed the drilled
small spanner nut on it. This held it in place while I threaded the shank. |
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This is the finished set. The larger bolt started out as a 12" long
carriage bolt. I removed the shoulder and shaped the head, drilled it, then
chucked it up backwards in the lathe. On my lathe there is room behind the
jaws for the carriage bolt head. I used a center drill, then drilled &
taped for the 1/4" bolt.
Note: the shank on a 1/2" bolt is .45", or about 7/16". Keep
the in mind when drilling the handles and brackets. |
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