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how to grind bolt head to proper diameter?

  1. #1
    Junior Member
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    how to grind bolt head to proper diameter?

    BACKGROUND (not necessary to know):

    My bike's an '88 EX500.

    On the back half of the left handlebar's control housing is a tab that plugs into a hole in the handlebar. This keeps the control housing from rotating. The tab has broken off and I need to replace it to keep the housing stationary.

    I'm going to insert a bolt into the housing where the tab used to be. The bolt's head will plug into the hole on the handlebar. The hole is about 3mm in diameter.

    I haven't been able to find a bolt with the proper-sized head diameter (it needs to be accurate or this repair won't work). I'm going to use a mild steel hex-head bolt... but the head of the bolt I'm going to use is just slightly larger than the hole. I need to grind it down about 0.5mm in diameter.

    MY QUESTION (finally):

    How can I grind the head of a mild steel hex-head bolt down about 0.5mm in diameter? (Or, if you read the above, do you have any other advice?)

    Thanks!

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    '88 Kawasaki EX500

  2. #2
    Lifer oreo_n2's Avatar
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    how to grind bolt head to proper diameter?

    bench grinder or right angle grinder or dremel????

    or am i misunderstanding the complexity of the problem?

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  3. #3
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    how to grind bolt head to proper diameter?

    Hmm... I was afraid you'd say that! I don't have any experience with those machines. I was hoping for a more low-tech way to do it. Do you think a metal file would work? Or would that be too slow?

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    '88 Kawasaki EX500

  4. #4
    Super Moderator beet's Avatar
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    file would work

    takes a long time if you can fit im not sure wtf your talking bout
    i think a bench grinders what your looking for or ask i think i might have what your looking for in my invatory of parts







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  5. #5
    Just Registered TLRMan's Avatar
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    how to grind bolt head to proper diameter?

    you need a 1/2 of a mm?

    Dude, that's only .020" in diameter..do you mean 5mm? >.1969?
    And yes I have the grinder to do it...you just gotta get it to me with the correct dimensions...

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  6. #6
    Lifer oreo_n2's Avatar
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    how to grind bolt head to proper diameter?

    after the holidays give me a shout, i could stop by with my dremel and tap set?
    it sounds like the problem could be solved pretty easily wth the right tool.

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