The set up for the first operation, face, turn thread diameter, chamfer, die thread and part off
![](resources/2012-09-17%2019.35.58.jpg.opt650x866o0%2C0s650x866.jpg)
The four water pump bolts are 1" under the hex head so the home made travelling steady tool was used to cut the thread diameter
![](resources/2012-09-18%2008.41.21.jpg.opt650x487o0%2C0s650x487.jpg)
![](resources/2012-09-18%2008.41.35.jpg.opt650x487o0%2C0s650x487.jpg)
![](resources/2012-09-18%2008.42.53.jpg.opt650x866o0%2C0s650x866.jpg)
First operation completed on the four pump bolts and the cylinder and motion plate bolts
![](resources/2012-09-18%2009.03.58.jpg.opt650x487o0%2C0s650x487.jpg)
Straddle Milling. Using two cutters to cut the hexagon head. The stub arbor had a 3/16" spacer made, to space the two cutters to give the required A/F size. This ment only three passes of the cutter rather than six for each bolt.
![](resources/2012-09-18%2011.08.28.jpg.opt650x866o0%2C0s650x866.jpg)
The screws are screwed into a mild steel jig and tightened with a pair of pliers in the indexing head to create the hexagon. Once machined the bolt is removed with a spanner The same jig is also used to fac the hexagon head to the correct length on the lathe.
![](resources/2012-09-18%2011.08.59.jpg.opt650x866o0%2C0s650x866.jpg)
Facing head to length.
![](resources/2012-09-18%2012.11.22.jpg.opt650x487o0%2C0s650x487.jpg)
Finished phosphor bronze cylinder bolt. 6BA x 3/8" with a 3/16 A/F head. 20 made in total
![](resources/2012-09-18%2012.52.19.jpg.opt650x487o0%2C0s650x487.jpg)
![](resources/2012-09-20%2006.50.07.jpg.opt650x487o0%2C0s650x487.jpg)
![](resources/2012-09-20%2006.46.50.jpg.opt650x866o0%2C0s650x866.jpg)
![](resources/2012-09-20%2006.47.35.jpg.opt650x866o0%2C0s650x866.jpg)