Hex Bolts

[Murray Kish]

OK.... first question for the FAQ....

I'd like to make some small hex bolts. I thought it would be pretty simple, but I must be doing something wrong...

I have some brass hex rod (small, not exactly sure of the exact size since I'm at work right now.... ) and I figured the lathe would easily cut a rounded section to represent the threaded part of the bolt, and then I'd just part it off. Or, just slice off a piece of hex rod to act just as a bolt head that would be surface mounted...

Well, the brass basically just deflected on me and wouldn'd cut properly. I had the cutter running pretty close to the chuck, but really couldn't get it to work out like I hoped.

Perhaps just too small?? I'm guessing about 1- 1.5mm diameter brass hex rod. I have steady rest, but fail to see how that would help here? Is this a job for the follower rest? (of course, that would be about the only stinkin attachment I DIDN'T buy with my order..... )


Murray

[freakray]

What speed were you rotating the rod at?

[Murray Kish]

Not very fast. I didn't pay too close attention, but most of the stuff I've been reading (from the Sherline propaganda....) says decrease speed, increase feed. So generally I've been in the bottom third/half of the speed control....


Should I wind it up and try high speed?

[mike@af]

I've had no problem cutting aluminum and brass bolts. I cut them "backwards". The shaft facing the tailstock, and the head towards the head stock. I also only cut a length of the shaft a few millimeters at a time. About 3mm at a time. So if the bolt is 9mm long, it will require three stages of 3mm long cuts at a time.



Those are some tiny nuts/bolts I've cut before out of 6061.

[MPWR]

You fiend, where'd you get the small dia hex rod? I've never been able to find it.

Turning small diameter rod is a bit of a learned skill. More than likely, you will need to do any cutting and parting very close to the chuck jaws- maybe with in 1/4" or so. Run the speed up fairly high, and take very light cuts. Be slow and gentle when moving the cutting bit. A live centre or steady rest isn't really going to help you. Learning to do small diameters is really a finesse thing as much as anything else. I seem to remember there's something about turning small diameters in the Joe Martin book, too.


Hey Mike- are those nuts cut to a hex head? How'd you cut that?

[cinqster]

Originally Posted by MPWR

You fiend, where'd you get the small dia hex rod? I've never been able to find it.

Someone on the board suggested recently that K&S do it but I've not found it in the UK so far. Must admit I hate working with brass and have also had issues with thin bar.

[mike@af]

Originally Posted by MPWR

Hey Mike- are those nuts cut to a hex head? How'd you cut that?

1/32" Ø Hex nuts. They were cut by making an index out of some 1/2"Ø Hex stock I had laying around. Basically, I made a force fit tool that the nut was lightly pressed on to. Milled it out. Popped it off with my X-Acto, and continued the motions until done.