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  1. #1
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    Default I need To Reduce The Thickness Of My Nuts

    I need to reduce the thickness of my nuts! I searched Google, but I don't think it understood my question properly!

    I have a synthesizer, and they have these jack plug sockets. My synth has over 200 jack plug sockets, and some are inputs, and others are outputs, and it gets confusing which is an input, and which is an output. So I bought some nuts called Bananuts which you can get in various colours, then I colour coded the Inputs as Blue, and the Outputs as red. However the Bananuts have a thickness that stopped the jacks from going in the holes securely. So I need to file down about 200 nuts.

    What's the easiest way to file down a large quantity of nuts?

    Thanks!

    Pincho Paxton

  2. #2
    BobL is offline Member: Blue and white apron brigade
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    Default

    Agricultural method = Belt sander
    Nicer method - lathe

  3. #3
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    Default

    These are them for those not familar...
    (made of Al)
    bananuts-gallery.jpg
    If you have not got access to a lathe, I would use a linisher, although you will need to make up a threaded part to hold them while either turning or linishing.
    However, I'm not sure that will get you very far. The slot through the front of the nut is deep enough that if you remove material from the back, the nut may not have enough strength to hold on.

    Michael

  4. #4
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    Default

    You may have bought the wrong version for your jack pin body type. They do a version with a tapered internal hole/face which would allow some pins to go in further (depending on diameter).

    Maybe try and change them ?

    The other alternative is to mount them in a collet and machine a recess with an end mill.

    You could also mount a nut of the correct thread in the lathe chuck and screw in each ring - this will set each unit up quickly for milling. Being alloy (I expect) there should only be a light load on the thread and they should unscrew again.

    Cheers Rob
    The worst that can happen is you will fail.
    But at least you tried.



  5. #5
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    Quote Originally Posted by nearnexus View Post
    You may have bought the wrong version for your jack pin body type. They do a version with a tapered internal hole/face which would allow some pins to go in further (depending on diameter).

    Maybe try and change them ?

    The other alternative is to mount them in a collet and machine a recess with an end mill.

    You could also mount a nut of the correct thread in the lathe chuck and screw in each ring - this will set each unit up quickly for milling. Being alloy (I expect) there should only be a light load on the thread and they should unscrew again.

    Cheers Rob
    Oh yeah, I never thought of the internal taper. I can't take the front off without losing the colour however. I was going to take the back off. I think also because of the grove in them I can't take much off the back either. So instead I will need to colour the jack sockets with paint or dye. I have started painting the sockets with Acrylic marker pens, but the colour isn't as good as the original Bananuts.

    Here's the actual synth.. I mean who's idea was it to make all the inputs, and outputs look the same?....
    BGSharedSysP-large.jpg

    So what is the best way to colour metal Sockets?

  6. #6
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    If you can remove say the nuts on the outputs, you could try a blueing process (which is more black than blue)
    There are some posts on the forum about it.

  7. #7
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    I might buy a linisher. Anyway thanks for all the ideas!

    I was thinking of buying this, because it has a stone wheel... what do you think? don't want to spend too much money...
    https://www.amazon.co.uk/Draper-0509...1&sr=8-11&th=1

    or this, which they say is more for woodwork...

    https://www.amazon.co.uk/Sealey-SM75...9152031&sr=8-1

    Now I need to find something to holds the nuts with.

    Bought this to hold the nuts....

    https://www.ebay.co.uk/itm/282974291363

  8. #8
    Join Date
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    Default

    Hi Pincho,

    Quote Originally Posted by Pincho Paxton View Post
    I might buy a linisher. Anyway thanks for all the ideas!

    I was thinking of buying this, because it has a stone wheel... what do you think? don't want to spend too much money...
    https://www.amazon.co.uk/Draper-0509...1&sr=8-11&th=1
    I've got one of those from either Aldi or Lidl can't remember which, Powerfix brand, only about £20. Though I must admit I've seen them in there recently for £29. Three year warranty / guarantee. Mine doesn’t run out till 2022.
    Best Regards:
    Baron J.

  9. #9
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    Quote Originally Posted by BaronJ View Post
    Hi Pincho,



    I've got one of those from either Aldi or Lidl can't remember which, Powerfix brand, only about £20. Though I must admit I've seen them in there recently for £29. Three year warranty / guarantee. Mine doesn’t run out till 2022.
    Yes, that's a good price! If I search for just bench grinders I can get them for £35. Is a grinder good for this job? I don't know much about metalwork.

  10. #10
    Join Date
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    Default

    Hi Pincho,

    You can pick up a double ended bench grinder for as little as £20 ! However I don't think that this will solve your problem satisfactorily.

    What you are really needing is a turning job doing on those nuts. But there are several issues involved. The most obvious one, is the minute you reduce the thickness you are going to remove the coloured anodising ! The next is once you have reduced the nut's thickness, have you got enough thread left to actually secure it. You need a minimum of two full threads in that nut, and there is still the possibility that it will break at the slot when you nip it up.

    Grinding or sanding is in my opinion a poor way to attempt to thin the nut.

    One possibility comes to mind and that is creating a cone in the face of the nut that will allow your plug to seat properly. But even so you will still loose the colour where its machined. This is still a turning process !

    Where about's in the UK are you ?
    Best Regards:
    Baron J.

  11. #11
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    Quote Originally Posted by BaronJ View Post
    Hi Pincho,

    Where about's in the UK are you ?
    I'm in Staffordshire, but I prefer to shop online. I don't have a car or anything, and I'm not travelling by bus with this virus around. I think I only need to get rid of about 2mm off the back. The jackplugs nearly fit, but they pop out if you tug them. Also the taper doesn't seem to make a difference, because the jack plugs have a flat face on them.

    I've got a Dremel, is that any good for this? I've got a Workmate bench.

  12. #12
    Join Date
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    Hi again,

    Normally people put an area in their profile so that it can be seen under the avatar !

    Quote Originally Posted by Pincho Paxton View Post
    I'm in Staffordshire, but I prefer to shop online. I don't have a car or anything, and I'm not travelling by bus with this virus around. I think I only need to get rid of about 2mm off the back. The jackplugs nearly fit, but they pop out if you tug them. Also the taper doesn't seem to make a difference, because the jack plugs have a flat face on them.

    What about this....
    https://www.amazon.co.uk/Polisher-Machine-Machining-Woodworking-Standard/dp/B088RCZ43B/ref=sr_1_1_sspa?dchild=1&keywords=lathe&q
    id=1594572416&sr=8-1-spons&psc=1&spLa=ZW5jcnlwdGVkUXVhbGlmaWVyPUFFOUFPSUtXQldUWEgmZW5jcnlwdGVkSWQ9QTAxMTgwMzMxTzNXVVlPWDkwOEtHJmVuY3J5cHRlZEFkSWQ9QTA5NTY5MDEzRUpQUTVERTRDRU1WJndpZGdldE5hbWU9c3BfYXRmJmFjdGlvbj1jbGlja1JlZGlyZWN0JmRvTm90TG9nQ2xpY2s9dHJ1ZQ==


    I used to work on CNC many years ago, I could probably remember enough to do this job.
    That is basically a motor with a drill chuck !

    Drop me a PM. We will take it from there.
    Best Regards:
    Baron J.

  13. #13
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    Exclamation

    Don't use a grinder. The aluminium can clog the wheel and then heat up, causing the wheel to crack (or explode). Use a linisher if you wish to reduce the thickness.

    Michael

  14. #14
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    Quote Originally Posted by Michael G View Post
    Don't use a grinder. The aluminium can clog the wheel and then heat up, causing the wheel to crack (or explode). Use a linisher if you wish to reduce the thickness.

    Michael
    OK Thanks!

  15. #15
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    So looking at the nuts only about 0.4mm can come off them. I am now looking at this...

    https://www.amazon.co.uk/gp/product/B074SX6MFM/ref=ox_sc_act_title_1?smid=AIJ4UOXKT6BLU&psc=1


    I don't know what belt to use with it for aluminium.

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