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Hex Nuts from Hex Bar
Forge

Created by

Forge

11. October 2026NO
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Hex Nuts from Hex Bar

A nut is a short piece of hexagon bar with a tapped hole through it. Drill and tap the end of the bar, saw off one nut's height, and repeat: the bar's flats are already the spanner size. The example is M6 to ISO 4032: 10 mm across the flats, 5.2 mm high, tapped M6 x 1.0 from a 5.0 mm hole. The notebook gives the bar, drill and height for M5 to M10.
Beginner
1 hour for 10 nuts

Instructions

1

Sizes

Loading Jupyter Notebook...
2

Square the end

Clamp the 10 mm A/F hex bar in the vise, saw the end square and file it flat.

Materials for this step:

Mild Steel Hex BarMild Steel Hex Bar0.2 meter

Tools needed:

Bench ViseBench Vise
HacksawHacksaw
File SetFile Set
3

Drill the tap hole

Clamp the bar upright in the machine vice under the drill press. Centre-punch the middle of the end and drill a 5.0 mm hole 20 mm deep, with a drop of cutting oil.

Materials for this step:

Cutting OilCutting Oil5 ml

Tools needed:

Drill PressDrill Press
Machine ViceMachine Vice
Drill Bit SetDrill Bit Set
Center PunchCenter Punch
Safety GlassesSafety Glasses
4

Chamfer the hole

Countersink the hole's mouth lightly, just past the thread's outer diameter.

Tools needed:

Countersink Bit SetCountersink Bit Set
Drill PressDrill Press
5

Tap M6

Start the M6 tap square in the tap wrench with oil. Turn half a turn in, a quarter back to break the chip, to the bottom of the hole.

Materials for this step:

Cutting OilCutting Oil5 ml

Tools needed:

Tap and Die SetTap and Die Set
Tap WrenchTap Wrench
Bench ViseBench Vise
6

Saw off a nut

Mark 5.2 mm from the end plus the saw's width, and saw it off square. File the cut face flat until the caliper reads 5.2 mm.

Tools needed:

ScriberScriber
Engineer's BlueEngineer's Blue
HacksawHacksaw
File SetFile Set
Digital Caliper 6-InchDigital Caliper 6-Inch
7

Chamfer and deburr

File a small chamfer on the corners of both faces and deburr the thread's ends.

Tools needed:

File SetFile Set
Deburring ToolDeburring Tool
8

Test and repeat

Run the nut down an M6 bolt by hand. Re-face the bar's end and repeat; one 20 mm hole gives three nuts.

Tools needed:

Hex Bolt AssortmentHex Bolt Assortment
9

Troubleshooting

Nut making troubleshooting.

Flow

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Materials

2

Tools Required

16

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