accurate hexagonal holes for bolt heads - Router Forums
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post #1 of 20 (permalink) Old 03-06-2013, 12:26 AM Thread Starter
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Default accurate hexagonal holes for bolt heads

Hello,

Have been inserting hexagonal nuts and bolt heads into home made knobs

Have tried using chisel, have tried using dremel, both were awkward but doable and my hexagons were a bit sloppy.

Can't help thinking there is a better way involving a jig or a template

Whilst googling the problem I found this thread

Photos Making hex head holes in knife handles - Page 3

with this video

hexagon hole drilling using the vika attachment. - YouTube

anybody use any other ways of cutting accurate hexagonal holes ?


Bill
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post #2 of 20 (permalink) Old 03-06-2013, 06:49 AM
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Hi Bill

Use square head bolts and nuts it will make your job easy..

McMaster-Carr
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Quote:
Originally Posted by steamingbill View Post
Hello,

Have been inserting hexagonal nuts and bolt heads into home made knobs

Have tried using chisel, have tried using dremel, both were awkward but doable and my hexagons were a bit sloppy.

Can't help thinking there is a better way involving a jig or a template

Whilst googling the problem I found this thread

Photos Making hex head holes in knife handles - Page 3

with this video

hexagon hole drilling using the vika attachment. - YouTube

anybody use any other ways of cutting accurate hexagonal holes ?


Bill



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post #3 of 20 (permalink) Old 03-06-2013, 07:42 AM
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Or alternatively don't use a bolt at all.

Rather use threaded rod and an insert and then epoxy the rod in place.
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post #4 of 20 (permalink) Old 03-06-2013, 07:48 AM
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Hi Bill,
Most of my knobs are cherry. I use 1/4"x20 bolts/nuts. I drill a hole with a 27/64" or 7/16" brad point bit 3/16" to 1/4" deep, then drill thru with a 1/4" bit. I pull the nut/bolt into the knob using a bolt/nut and fender washer. makes a nice tight, clean fit,
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post #5 of 20 (permalink) Old 03-06-2013, 09:26 AM
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Bill,
I make mine exactly like Michael. It works very well.
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post #6 of 20 (permalink) Old 03-06-2013, 12:29 PM
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You are saying you want that hex bolt head showing, am I right?

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post #7 of 20 (permalink) Old 03-06-2013, 12:34 PM
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Hi all
exactly like Michael.

Member of the french site for woodworkers
www.lescopeaux.asso.fr
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post #8 of 20 (permalink) Old 03-06-2013, 08:23 PM Thread Starter
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Default Hexagonal holes

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Originally Posted by JOAT View Post
You are saying you want that hex bolt head showing, am I right?
Hello,

Thanks for all of the responses.

No the hex head wont show - I'm the only one that will know how sloppy they are.

Was simply wondering how to do the job better, am fairly sure that others would do a much tidier job than what I have done. The post was basically a "fishing trip" to initiate some discussion and find out how others approach this sort of job. ie make a clean blind excavation of a specific shape in some timber and put in a tight fitting metal insert.

If I go slow and careful with a narrow sharp chisel it looks ok but its fairly easy to slightly overcut one edge and on such a small hole even a little mistake is a big %age of the hole size and just looks ugly

FYI on another thread somebody recommended this parser tool Two Legged Parser

I thought the funny hex drill bit in the video I found is an amazing and interesting bit of gear

Metalworkers have tools called broaches that seem to do this sort of shaped blind hole very well.

I wasn't sure about how well epoxy would grip a bare threaded bar and I will give that a shot .

Thanks again for all of the various responses.


Bill
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post #9 of 20 (permalink) Old 03-11-2013, 06:13 AM
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Quote:
Originally Posted by steamingbill View Post
No the hex head wont show - I'm the only one that will know how sloppy they are.
Ah. In that case, if it was me doing it, I'd probably just drill a round hole, then use JB Weld.

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post #10 of 20 (permalink) Old 03-12-2013, 04:58 PM
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Hey guys, this IS a router forum, why didn't anybody suggest a template???

I finally had the chance to draw one up. Drew the hexes then offset the size by 1/8" to allow the use of a 1/8" straight bit and a 3/8" bushing. Will leave a bit of material in the corners, should be enough to hold the nut in place while glue sets, or while the cover piece is glued in place. Sizes range from a 1/4" up to 1" by 16ths.

I suppose if you wanted, you could size it for a 1/16" bit and 5/16" bushing for the smaller size nuts.

If you attach the pattern to 1/4" plexiglass, scribe the alignment lines with a utility knife, then cut the outer hexes with a scroll saw, you should be good to go. Other material would work, just would be easier to align using plexi with scribed lines.

Mike "Dodis"
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