I ordered a replacement thruaxle and instead of 100mm I received 110mm, the 15mm diameter, TL and TP is all correct. I know I could just return it and wait for a replacement but I want to run a theory by everyone here first. If I shorten it by 10mm then using a tap and die, re-cut new threads(I have the correct parts to cut the exact same threads as the original) would this be ok or would it be a problem? I'm replacing the front thruaxle on a 2021 Salsa Cutthroat with rigid carbon fork. The replacement thruaxle I bought was made for Rockshox suspension fork, my fork is stock rigid. Do I have 2 problems here or 1. is the axle I ordered compatible just too long and/or 2. The Rockshox axle is/isn't compatible with my rigid stock carbon front fork?
. As an experiment, I used a blank steel rod and with the tap and die, cut threads that looked machine made, why isn't there more talk of people cutting their own thruaxles instead of paying $60 from RAProject or other companies who make good products, just charge a lot for them.

Thankyou in advance.

Most people simply don't have thread taps and dies kicking around. Thru' axles also usually last forever, so there isn't much demand for replacements.

Are the original threads cut or rolled?

If you ordered from RAP, their customer service is second to none!
Contact them, they will set you up and quickly

Barry

A tap is for internal threads. A die is for external threads. The major diameter of an external thread is smaller than the nominal 15mm. I measured one of my 12mm axles and it is a little smaller than 12mm, so you may get by with making the threaded length longer first, then cutting the axle to length and chamfering the end to the thread's minor diameter. Without the original threads to guide the die, new threads would likely end up crooked.

As noted, dies and die handles aren't cheap and the need for different lengths isn't large. My frames all came with axles that fit.

ISO Metric Thread | Metric Thread Chart | Apollo International

You're kidding, right?

A lot of thru-axles are hollow & thoroughly machined to use the absolute minimum of material necessary for the job. Cutting new threads over the hollow portion may well form a spring where the unwanted material was removed.

If you already have the tools, why not make your own from a solid rod. That'd be some bragging rights, right there.

I once saw a YouTube prank video where a guy tried to troll a bike shop into upgrading a QR bike with a thru-axle wheel set. The key was making thru-axles with 9.5mm nutted axle threads or QR end shape or some such shenanigans.