Buzz
An angle grinder is the most effective tool for shortening exposed bolt ends. Here’s how you can do it.
To get started, you'll need a bench vise and an angle grinder equipped with a metal cut-off wheel. Mark the cutting point with a Sharpie, then secure the bolt's head in the vise. Before cutting, screw a nut onto the base of the bolt; this will help align the threads once you’re done. With the grinder running, approach the bolt at a flat angle and cut through it carefully.
After the cut, use a bench grinder or abrasive pad to smooth the bolt’s end, and then unscrew the nut with a wrench.
Allow the bolt to cool for a few seconds before touching it, as it will be very hot right after cutting.
Always wear safety glasses when operating an angle grinder, and make sure to check the position of the grinder's guard to direct sparks safely. Remove any flammable materials from your work area to prevent fire hazards.
