Uploaded September 2026 | Updated September 2026, 2 hours ago
We’ve all been here before. You need a shorter bolt, but every bolt you have is too long. So it’s time for the hacksaw. But before cutting, we need to figure out exactly where to cut.
When it’s possible, install the bolt exactly as it will be used, including any washers. Tighten the nut and use a marker to color the first two exposed threads. Later, when we get this in the vise, we’ll cut on the waste side of those threads.
Now we’ll remove the bolt and add a nut, threading it toward the bolt head and beyond the mark we added. This will become very important later.
But when it comes time to cut the bolt, how do we grip it? If we’re cutting off a large section, we can simply flip the bolt around and clamp the part we don’t plan to keep.
But if we’re only removing a small amount, there may not be enough waste for the vise to grip. That means we’ll need to stand the bolt vertically and clamp the part we’re keeping. Clamping it directly in the vise can crush or flatten the threading—and the bolt may still move while we’re cutting.
There are a couple ways around this. The first is to grab two pieces of wood and sandwich the bolt between them in the vise. The wood protects the threads while also helping grip the bolt.
But a method I really like is to use a coupling nut that I cut in half, reusing the two halves as threaded vise jaws. Because they match and cradle the threads, they spread the clamping pressure across a larger area. We can clamp the bolt firmly without the vise teeth digging into the threads.
Now we can grab the hacksaw and cut through the first unwanted thread. After the cut, lightly file a small chamfer around the end. We’re only removing the sharp edge and any large burrs—not grinding away an entire thread.
Finally, remove the bolt and back off the nut we added earlier. Because it approaches the cut from the undamaged side, it helps clear the remaining burrs and reform minor damage to the starting thread.
Now you’ve sized the bolt, protected the threads, cleaned up the cut—and it’s ready to use.
“As usual, the nut gets stuck cleaning up after the saw.”
Like step by step projects? Check out the second channel! → @makethingswithrob
Buy me a beverage! → buymeacoffee.com/makethings ←
Become a patron! → patreon.com/makethings ←
Huge thank you to my patrons that keep this thing going!
*MAKER TEAM*
Michelle B
Keith Current
Rich Lightfoot
Tutor the Barbarian
Aubrey G.
Nukebert
Sam W.
Aaron Knows DIY
G. Salazar
David B.
Marc B.
Richard B.
Ben. K
Bill Patterson
D. Lundman
Make Things
#MakeThings #mtbitesize
We’ve all been here before. You need a shorter bolt, but every bolt you have is too long. So it’s time for the hacksaw. But before cutting, we need to figure out exactly where to cut.
When it’s possible, install the bolt exactly as it will be used, including any washers. Tighten the nut and use a marker to color the first two exposed threads. Later, when we get this in the vise, we’ll cut on the waste side of those threads.
Now we’ll remove the bolt and add a nut, threading it toward the bolt head and beyond the mark we added. This will become very important later.
But when it comes time to cut the bolt, how do we grip it? If we’re cutting off a large section, we can simply flip the bolt around and clamp the part we don’t plan to keep.
But if we’re only removing a small amount, there may not be enough waste for the vise to grip. That means we’ll need to stand the bolt vertically and clamp the part we’re keeping. Clamping it directly in the vise can crush or flatten the threading—and the bolt may still move while we’re cutting.
There are a couple ways around this. The first is to grab two pieces of wood and sandwich the bolt between them in the vise. The wood protects the threads while also helping grip the bolt.
But a method I really like is to use a coupling nut that I cut in half, reusing the two halves as threaded vise jaws. Because they match and cradle the threads, they spread the clamping pressure across a larger area. We can clamp the bolt firmly without the vise teeth digging into the threads.
Now we can grab the hacksaw and cut through the first unwanted thread. After the cut, lightly file a small chamfer around the end. We’re only removing the sharp edge and any large burrs—not grinding away an entire thread.
Finally, remove the bolt and back off the nut we added earlier. Because it approaches the cut from the undamaged side, it helps clear the remaining burrs and reform minor damage to the starting thread.
Now you’ve sized the bolt, protected the threads, cleaned up the cut—and it’s ready to use.
“As usual, the nut gets stuck cleaning up after the saw.”
Like step by step projects? Check out the second channel! → @makethingswithrob
Buy me a beverage! → buymeacoffee.com/makethings ←
Become a patron! → patreon.com/makethings ←
Huge thank you to my patrons that keep this thing going!
*MAKER TEAM*
Michelle B
Keith Current
Rich Lightfoot
Tutor the Barbarian
Aubrey G.
Nukebert
Sam W.
Aaron Knows DIY
G. Salazar
David B.
Marc B.
Richard B.
Ben. K
Bill Patterson
D. Lundman
Make Things
#MakeThings #mtbitesize
