Pinhead skewers: how to shorten it
#3
Goathead Magnet
Joined: Nov 2005
Posts: 673
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From: Albuquerque, NM
Bikes: Surly LHT, Cannondale Caffeine F3
If you need to just cut the threaded part shorter, the easy way is to thread a nut (preferably not the nut you'll use with it on the bike, but it'll work if it's all you can get), hacksaw the threads, file them down so there aren't any sharp edges, then take the nut off. The nut will straighten out the last little bit of the thread so that your regular nut will go right on. A slightly more elegant method is to cut and file the threaded part, then file a 45 degree chamfer on to slightly below the deepest part of the threads - if you're decent with a file, you can get the nut on easily without leaving a possible sharp burr.
If you need the threads longer, it's another matter entirely. You could get a die (which is likely to be expensive - you'll need one that's adjustable, not one of the hexagonal dies that you'll find in most hardware stores that are designed only for cleaning up threads), you'll need a die handle, you'll need threading oil (preferably sulfurized, but anything with plenty of EP additives should be fine) and you'll need tools to hold the skewer still while you cut the threads. The threads you cut will weaken the skewer, possibly putting it at risk for future breakage. You also might have to contend with hardened steel, possibly only on the outer surfaces or possibly through the thickness of the skewer. In short, I wouldn't suggest cutting the threads longer, if that's what you have in mind.
If you need the threads longer, it's another matter entirely. You could get a die (which is likely to be expensive - you'll need one that's adjustable, not one of the hexagonal dies that you'll find in most hardware stores that are designed only for cleaning up threads), you'll need a die handle, you'll need threading oil (preferably sulfurized, but anything with plenty of EP additives should be fine) and you'll need tools to hold the skewer still while you cut the threads. The threads you cut will weaken the skewer, possibly putting it at risk for future breakage. You also might have to contend with hardened steel, possibly only on the outer surfaces or possibly through the thickness of the skewer. In short, I wouldn't suggest cutting the threads longer, if that's what you have in mind.
#4
Senior Member
Joined: Aug 2007
Posts: 501
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From: USA
Note that you probably do not want to cut it off flush with the surface of the security nut. It is much easier to use the security "key" to tighten or loosen the security nut if there is at least 1/8" to 1/4" protruding because the security key then stays centered on the protruding bolt. This makes it easier to keep the key engaged on the indentations in the nut. Just cover the exposed end of the bolt with the rubber tips they include or, if you lost them, any good hardware store should stock these low-cost end caps.
#7
Goathead Magnet
Joined: Nov 2005
Posts: 673
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From: Albuquerque, NM
Bikes: Surly LHT, Cannondale Caffeine F3

A hacksaw blade and a small file should be available for under $10 total for both. In a pinch, you might be able to make do with just the hacksaw blade (about a dollar) and some emery boards like what are used to smooth fingernails - I've never tried them for metal finishing, but they'd probably do just fine (and likely cost just a couple of dollars for a package).
#9
Goathead Magnet
Joined: Nov 2005
Posts: 673
Likes: 11
From: Albuquerque, NM
Bikes: Surly LHT, Cannondale Caffeine F3
Nonadjustable hex dies are for chasing threads, not cutting them.Rolled threads are stronger and typically lack sharp points in the bottoms of the threads, so they're not as much of a stress riser as cut threads, generally leading to better fatigue performance. You're quite right, cut threads are unlikely on a skewer.
No die should be required for shortening threads, though.
#10
Thread Starter
Senior Member

Joined: May 2010
Posts: 73
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From: Burnaby, BC
Done! And a success! Took it to a guy at work. We put it in a vise and tried a hacksaw. (He put a nut on it first.) The blade was too dull, so he dremeled it. And I filed down any sharp points. Got it on the bike. Should be good.
Thank you all for your support.
Thank you all for your support.
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