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I also mark (Sharpie) and cut with a cutoff wheel. I can usually hand-chamfer and then wire-wheel to an acceptable end.Great minds think alike. On my list of things to do it find an appropriate die to rethread those bolts after I grind them off. With the nyloc nuts you gotta be careful to not over heat and melt the nylon so I usually mark the bolt with a file then remove them and cut them AFTER threading a die onto the bolt. 5/16 is too heavy to easily cut with bolt cutters...at least for me. A lot of extra work but worth it.
NRS probably buys bulk bolts that fit in a variety of locations on their products. That length is hazardous for sure in that application. U bolts do allow fine tuning easily as necessary.
Have you priced stainless acorns lately? I need 2 and went to the Homey place...1/2" were $4.50 EACH!!
Grind and buff with a Scotchbrite wheel and a squirt of locktite if the nylon melts.
I want to try one of these external debur/chamfer bits.
One can also thread on a non-locking nut, cut the threads slightly long, and when you unthread the nut, it will push the burr out of the threads...then file/grind/etc the chamfer. You can't really skip the chamfer and be able to thread a nut back on.
I get most of my hardware from Bolt Depot, McMaster, or Amazon
$12/10 on McMaster
$9/20 on Amazon