1. TECHNIQUE
ALL LEVELS | METAL
Microfasteners are
manufactured in various
metals and sizes.
The Nuts & Bolts
of Threaded Connections
Learn how to use tap and die tools to make cold connections in jewelry.
by Jill L. Erickson
T
here are times when you want to connect two convenient for you to switch out design elements in a
components but not necessarily permanently. piece of jewelry, make repairs, and add moveable parts.
Or, maybe you want to attach a somewhat fragile And, of course, they look cool.
component that wouldn’t withstand the pressure of How do you achieve the nut-and-bolt connection?
a rivet. What you need in these scenarios is a more With tap and die tools. Yes, there’s a learning curve.
forgiving cold connection: the nut-and-bolt connection. You’ll have to master the art of using miniature tap and
Think of the versatility: Threaded connections allow you die tools and reading measurement charts. But it’s worth
to disassemble components, giving you easy access to the effort. There’s nothing quite like the oomph and
them for cleaning. Threaded connections also make it options that nuts and bolts bring to jewelry designs.
© 2010 Kalmbach Publishing Co. This material may not be reproduced in any form
64 Art Jewelry ■ May 2010
without permission from the publisher. www.ArtJewelryMag.com

2. To prevent taps and
threading dies from
Meet the tools binding or breaking
as you use them to
In this section, we’ll introduce you to typical tap and die tools and walk you cut threads, you must
through three basic things you can do with these tools: make a hole without keep them lubricated.
threads, “tap” a hole (make a hole with threads), and “thread” a rod (use a die to
make threads on a wire/rod). For more terminology, check out the “Threaded
Connections At-A-Glance Glossary,” page 66.
Threadless holes
You don’t always have to
thread a hole in order to
connect pieces with nuts
and bolts. The hole just
+ + = needs to be the proper
diameter, and you’ll need
to add a washer to each
side of the assembly to
make sure the connec-
tion is secure.
Clearance drill bit
Flex shaft Nut driver
or Tapped holes
(threaded holes)
Threaded holes engage
the threads of a bolt.
Tap wrench and tap
You can secure this kind
+ or = of connection with just
a nut at the back of
your assembly.
T-handle tap holder
and tap
Flex shaft and
tap drill bit E-Z Tap and Die Holder and tap
Threaded rods
E-Z Tap and Die Making your own
Holder and threaded rods (bolts)
threading die
is optional. You can
+ or = buy premachined bolts
(and corresponding nuts).
If you make your own
Die stock and threaded rod for bolts,
threading die you can customize the
diameter and length to
Wire/ fit your design.
rod
65

3. Terminology Nuts
Threaded connections are all about the functional beauty of the ascending spiral.
When a spiral is cut into a metal hole (tapping) or cut around a piece of rod (thread-
ing), you’ve got the makings of nuts and bolts. First, though, it’s helpful to get
acquainted with the vocabulary and tools associated with these cold connections.
Washers
threaded connections
at-a-glance glossary
Back off To turn a tap Kerf Slit or notch made Pilot hole Drilled
or threading die counter- by a saw blade; some bolt opening made to help
clockwise to allow for the heads have a slit to accom- guide a tap as it cuts Bolts
removal of swarf and to modate a screwdriver threads into the metal;
prevent overstressing or pilot holes are smaller
Lubricant Oil used to
breaking the tool than the tap
help prevent taps and
Bench vise Tool that threading dies from Strip To damage or tear
clamps to a workbench binding as they cut metal the threads of a nut, bolt, Hex-head Round
and has two adjustable or threading die
Machinist’s square
jaws for gripping objects
Tool used to measure Swarf Metal fragments
Bolt Threaded rod with a a 90° angle created when metal is cut
head on one end; paired or ground Fillister
National Coarse (N/C)
with a nut Flat
U.S. measurement system Tap Tool used to cut
Clearance drill bit Cuts for thread sizes used in threads into the wall of
a hole that is just large general-purpose applica- a hole
enough for a bolt to pass tions. The “N” relates to
through without the bolt’s the diameter of the bolt or
Tap drill bit Cuts a pilot
hole that is proportionate ordering tools
threads touching the walls screw; “C” identifies the
of the hole number of threads per
in size to your selected tap and supplies
inch. For example, N/C Tap drill chart Identifies When you’re ordering tools and
Countersink To set the
10/24 is the same diameter the measurements of
head of a bolt or screw supplies, make sure to match sizes of
as N/C 10/32, but the compatible taps, threading
flush with or below the tap drill bits, which make pilot holes,
10/24 has fewer threads dies, tap drill bits, and wire/
surface of a pilot hole; to the taps that cut threads into
than the 10/32. rod stock
slightly enlarging the the inside walls of pilot holes. Also,
outer edge of a pilot hole National Fine Series (N/F) Tap wrench/T-handle
threading dies, which cut threads on
with a ball or bud bur U.S. measurement system tap Devices that hold a
tap securely, acting as a the outside of rod or wire, will need
allows you to countersink for thread sizes used in
the bolt or screw precision applications like handle during tapping to fit the gauge of your rod or wire.
jewelry making. The “N” Suppliers that sell taps, dies, tap
Die see threading die Tapping Cutting threads
number can be a relative drill bits, and clearance drill bits can
into the walls of a pilot hole
Die stock Tool that holds number like “0” or “00.” help you select matching sets of
a threading die, acting as a N/F sizes have more Threaded rod Rod that’s tools. Most suppliers have tap and
handle as you cut threads threads per inch than had threads cut into it, but
drill charts to take the guesswork
on wire/rod N/C sizes. A typical N/F does not have a bolt head
out of selecting compatible tools for
E-Z Tap and Die Holder size is N/F 0/80. Fasteners Threading Using a die to your specific project. It’s also helpful
Dual-use tool that secures with these high thread cut threads on wire/rod to have a B&S wire gauge and a drill
miniature taps and counts provide solid
Threading die Tool used bit gauge. Ready-to-use machined
threading dies in sizes holding power.
to cut threads on wire/rod nuts and bolts are available from
N/F 00/90, 0/80, 1/72, and Nut Fastener with an
Washer Flat, thin ring some suppliers.
size N/C 2/56 internal thread that screws
used in a nut-and-bolt
Gauge Unit of measure onto a bolt to tighten or
assembly to ensure a
that describes the thick- hold something
tight connection
ness of wire or metal; a Nut driver (or socket online extra
tool used in measurement, Wire/rod Metal stock that
wrench) Holds a hex- Download a free PDF of the
such as a B&S gauge is cut with a threading die
head bolt and/or nut to
to make bolts “Threaded Connections At-A-Glance
permit tightening
Glossary” at www.artjewelry
mag.com/reference.
66 Art Jewelry ■ May 2010

4. The assembled pendant is
E-Z Tap and Die 21 ⁄4 x 11 ⁄2 in. (57 x 38 mm).
Holder and tap
Part 1: Tapping
materials
Planning your design ■ Copper sheet: 18-gauge (1.0 mm),
I sketched out a design for a pendant with 2 x 2 in. (51 x 51 mm)
interchangeable enamel copper disks. To ■ N/F 0/80 bolts (choose from): hex,
make the disks interchangeable, I planned round, flat, or fillister
to use nuts and bolts to attach them to a ■ N/F 0/80 nuts
backplate. I chose 18-gauge (1.0 mm) ■ Washers (optional)
copper sheet for the backplate, because
toolboxes, page 75
it’s an appropriate gauge to use for making
■ Riveting
threaded holes to fit N/F 0/80 ready-made
■ Sawing/piercing
nuts and bolts.
additional tools & supplies
TIP: To make sure that you buy selected a #52 clearance drill bit to make ■ Drill-bit gauge (optional)
bolts that are long enough to fit holes in the center of my domed copper ■ Clearance drill bit: #52
through all the layers of your disks. After drilling the clearance holes in ■ Scribe
finished jewelry piece, measure the disks, I cleaned them and fused layers ■ Tap drill bit
first. Stack your finished compo- of bright enamels on the concave side of ■ Tap: 0/80
nents, any sheet stock that you’ll the disks . ■ Tap holder (to fit 0/80 tap)
make into components, and any ■ Anchor lube
washers and nuts you plan to use. NOTE: You don’t need to make tapped ■ Machinist’s square or level
■ Sandpaper: various grits
Then, use a brass gauge to (threaded) holes if you plan to use washers
■ 2 nut drivers (for 0/80 hex bolts
measure the total thickness of the with your microbolts and nuts. You can
and nuts)
stack, and order bolts that are simply use a clearance bit and bolts in the ■ Jeweler’s screwdriver
longer than that. appropriate size and assemble your
components with nuts and washers. optional materials,
Making clearance holes tools & supplies
(no threads) ■ Brass rod: 14-gauge (1.6 mm),
I decided to use a clearance drill bit for online tutorials 6 in. (15.2 cm)
making holes in the center of my domed To learn the basic skills required to ■ Threading die: 0/80
copper disks, because I would not be make the enameled disks for this ■ Die stock or die holder
cutting threads in the disks due to my plan project, go to www.artjewelry (for 0/80 die)
to fuse enamel on the metal. (Tapping a mag.com/videos to watch ■ Ring clamp
hole before I enameled the disk made little demonstrations of the following ■ Riveting block
techniques: using a disk cutter, ■ Pin vise
sense because stray grains of powdered
doming disks with a dapping ■ Loctite or cyanoacrylate glue
enamel could easily fuse to the inside of a
■ Soldering pen
threaded hole. And trying to tap a hole block and punches, using a
that’s surrounded by fragile fused enamel center punch, drilling metal,
Find out where to buy supplies,
didn’t seem too logical either.) and enameling basics. page 79
Referencing my supplier’s charts, I See Safety Basics, page 74
www.ArtJewelryMag.com 67

5. E-Z Tap and
Allen wrench Die Holder
1
Set screw
4
Bushing Prepare the tap. Secure a tap in a tap
holder. I used an E-Z Tap and Die Holder
[3], because it provides a sensitive touch
for tapping very small holes. Apply a drop
of lubricant to the tap. Using a machinist’s
square, position the tap perpendicular to
Tap the sheet, above one of the pilot holes
[Figure 2] [4].
2 3 Tap the holes. Gently rotate the tap
clockwise one rotation or until you feel
Tapping (threading) holes Drill pilot holes in the backplate. resistance. Back off by rotating the tap
If your design requires you to tap match- Place the sheet on a bench block, and use counterclockwise one-half rotation; this
ing holes through a front and back panel, a center punch to make a dimple at each removes swarf and prevents the tap from
see “Stacked Tapping,” opposite, for a mark. Insert the sheet marked-side up in becoming overstressed. Keeping the tap
quick tutorial. a vise; make sure that the sheet is level. lubricated, repeat these clockwise/
I decided to tap holes in my backplate counterclockwise rotations until the tap
so I could use bolts to secure my enameled NOTE: Securing the metal sheet in a vise emerges from the bottom of the hole.
disks to the backplate. before you drill it is a safety precaution Carefully back out the tap.
that prevents the metal from becoming
Mark the position of the pilot holes for a dangerous spinning projectile. NOTE: Taps are brittle. Using force
the backplate. Use a fine-tip marker or will result in a snapped tap. Be patient,
scribe to mark the desired location of the Insert a tap drill bit of the appropriate use lubricant, and back off when you
pilot holes on 18-gauge (1.0 mm) metal size into your flex shaft. I used a #55 tap feel resistance.
sheet [1]. drill bit because it’s the size specified for
0/80 taps. Lubricate the bit. Keeping the Repeat the process to tap the remain-
NOTE: Mark pilot holes on a rectangular or bit perpendicular to the sheet [Figure 1], ing holes.
square piece of sheet; later you’ll need to drill a pilot hole through one of the
secure the sheet in a bench vise, and dimpled marks [2]. Repeat to drill pilot Prepare the sheet for assembly. Using a
irregular shapes are hard to secure. holes through the remaining marks. jeweler’s saw and a 2/0 blade B , cut the
sheet to your desired backplate shape.
Add your chosen findings. Then file and
sand B the backplate.
suggested reading
Machinist’s One Good Turn: A Natural History of the
square Screwdriver and the Screw by Witold
Tap Rybczynski
90°
90°
Figure 1 Figure 2
68 Art Jewelry ■ May 2010

6. 5 6 7
Assembling components
Use bolts and nuts to attach components.
If you’re using a hex-head bolt to attach stacked
tapping
components, use a nut driver to turn the
bolt through the threaded hole [5]. Add
a nut to the end of the bolt [6]. While
holding the nut driver on the bolt head, If you want to use bolts to connect a
use another nut driver to tighten the nut piece that has front and back panels,
you’ll need to keep the panels aligned
at the back of the assembly.
and stacked as you tap (thread) them.
Use a jeweler’s screwdriver to drive
bolts that have a slot in the head [7]. [1] Make a metal sheet “sandwich.” Stack two metal
For tips on how to cut down the sheets of identical size, and tape them together with
length of a bolt, see “Cutting a Bolt painter’s tape to make a “sandwich.”
Down to Size,” below.
[2] Mark and center punch the top sheet. Mark
the location for holes in the top metal sheet. Use a
center punch to dimple the marks. Secure the taped,
Videos & Basics marked, and dimpled sandwich in a bench vise with
Check out these bonus tutorials the marks facing up.
for fundamental techniques used
[3] Drill pilot holes. Starting at one dimple, drill
in this project:
through both layers of sheet metal. Insert a piece of
snug-fitting wire or tubing into the hole; this will
• Drilling through metal keep the two sheets aligned.
• Sawing B
• Sanding B Repeat to drill and fit wire or tubing into the next hole. Repeat until all the pilot
• Setting wire rivets B holes are drilled through both layers of sheet.
B Basics, page 73 [4] Tap the holes. Remove the wire or tubing from one hole. Lubricate your
Videos, www.artjewelrymag. tap, and tap through both layers of sheet. Thread a bolt through the tapped
com/videos hole to maintain alignment of the two sheets. Repeat on the remaining holes.
cutting a bolt down to size
When you’re using premade bolts, you might [2] Use an extra-fine marker to mark the bolt
have to purchase a longer bolt than your where you want to cut it.
assembly requires. Here’s one way to cut the [3] Disassemble the components.
bolt to the correct size. [4] Screw the nut back in place on the bolt,
using the mark as a guide.
NOTE: Do not use wire cutters to trim a bolt; [5] Secure the head of the bolt in a ring clamp.
they will deform the bolt and strip the threads. [6] Use a jeweler’s saw and blade to cut off the
end of the bolt [Photo].
[1] Assemble your components, including [7] Unscrew the nut; this helps to maintain the
the nut. integrity of the threads at the end of the bolt.
www.ArtJewelryMag.com 69

7. E-Z Tap and Die
2
Holder and
1 threading die
Part 2: Threading a rod
making threaded
So, now you’re a threaded-connections This particular threading die has a ring that connections
diehard and you want to make your own
bolts. You’ll need a tool called a “threading
slides up and down the shank, allowing
you to adjust the size of the cutting more
die” and a device called a “die stock,”
which holds the threading die (see
opening. This feature makes it easier to
fit the die to the rod you are threading.
permanent
Maybe you have no intention of
“Threaded Connections At-A-Glance
disassembling threaded connec-
Glossary,” page 66). Cut threads into the rod. Add a drop of tions because you used them for
lubricant to the jaws of the die. Keeping purely aesthetic reasons. To make
Select the rod and die. Referencing your the die directly over the rod, turn the die these connections permanent, you
supplier’s charts, buy a die that corre- holder or die stock clockwise one rotation have a couple of options.
sponds to the gauge of rod you want to or until you feel resistance. Back off, and
cut threads into. I used 14-gauge (1.6 mm) turn the die counterclockwise one half- 1. Use a riveting hammer to tap
brass rod, which corresponds to my rotation. Add lubricant and repeat these the end of the bolt to turn it into
supplier’s 0/80 threading die. forward and backward rotations until a rivet.
you’ve threaded the length of the rod. 2. Apply a tiny drop of Loctite or
Round the end of the rod. Secure the
cyanoacrylate glue to the bolt
threads just before you assemble
rod in a ring clamp. Use a flex shaft and Make a head on the bolt. Insert the
your piece.
a cup bur to round the end of the rod [1]. threaded rod into a riveting block, leaving
Or, use a needle file to slightly round and about 1 mm of the rod exposed. Use a NOTE: If you later decide to
taper the end of the rod. riveting hammer to spread the end of the disassemble the piece, and if it
rod [2], as you would when setting a wire can safely withstand the heat of
Prepare the rod for threading. Secure rivet B . Using the flat head of a ball-peen a soldering pen, you can heat
the rod in a bench vise. Make sure the rod hammer, strike the spread edges of the the glue with the pen to break
is perpendicular to the vise [Figure 3]. rod, creating a slightly domed head. the glue’s bond.
Prepare the die. Secure the threading die Cut a slit into the head. Secure the non- 3. If your assembly can withstand
[Figure 4] in the die stock or die holder. hammered end of the rod in a ring clamp
the heat of a torch, solder the nut-
and-bolt connections with a
or a pin vise. Support the clamp against
pallion of easy solder.
your bench pin. Using a jeweler’s saw and
a 1/0 blade, cut a slit into the head. Check
Threading die that your jeweler’s screwdriver fits into the
slit. If necessary, use the saw and blade to
widen the slit. Remove the rod from the acknowledgements
clamp. A sincere thank you to Frankie
Wire/rod 90° Flood, assistant professor and
director of foundations in the
jewelry/metalsmithing department
Jaws at the University of Wisconsin–
Milwaukee, for his technical advice
during the writing of this article.
Adjustable ring
Thanks also to Bill Seeley at
Threading wire/rod with a die (opens/closes jaws) Reactive Metals for his expert tips.
Figure 3 Figure 4
70 Art Jewelry ■ May 2010

8. ■ contacts & suppliers | where to find it
contacts
When contacting artists via e-mail, please
put “Art Jewelry” in the subject line.
Artist Profile
page 41
■ Amy Roper Lyons,
www.amyroperlyons.com
GAllery
page 45
■ Colleen Baran,
50
colleenbaran@hotmail.com
■ Kristin Beeler, akbeeler@gmail.com Breeze throuGh A wire
■ Maggie Bergman, dAisy ChAin
www.play-design-create.com page 50
■ Michelle Dickman, budilia@yahoo.com ■ Razor flush cutters (Tronex Technology
■ Cheryl Eve, www.cheryleve.com Inc., www.tronextools.com)
■ Mary Filapek & Lou Ann Townsend, ■ Silver-plated ParaWire (Paramount Wire
www.maryandlouann.com Company, www.parawire.com)
■ Mark Lasater, clamshell@cableone.net ■ Silver-plated copper wire (Artistic Wire,
■ Marina Marioni, www.artisticwire.com; Beadalon,
marinamarioni@hotmail.com www.beadalon.com)
■ Tim O’Neill, www.artisangal.com ■ Gold craft wire (WalMart,
■ So Young Park, www.walmart.com)
www.soyoungparkstudio.com
■ Marthe Roberts/Shea, try
intArsiA:
www.jewelrybymars.com
Jan Smith, jan_ssi@hotmail.com
Puzzle 60
stone
■
into A
PAttern
45 page 60
■ Hot Stuff glue,
Super-T Medium
(Satellite City Inc.,
www.caglue.com)
■ Genie Gem Maker combination
machine (Diamond Pacific,
www.diamondpacific.com)
Beyond Jewelry
page 82 the nuts And Bolts of
■ Lynette Andreasen, threAded ConneCtions
www.lynetteandreasen.com page 64
■ EZ Tap and Die Holder, taps, dies, micro
suppliers bolts, nuts, drill bits, cup burs, socket
wrench, threaded rod (Reactive Metals,
For contact information for project authors, 800.876.3434, www.reactivemetals.com)
see Contributors, page 8. ■ T-handle tap holder, die stock, taps, dies
(Micro-Mark, 800.225.1066,
Coreless ConstruCtion: www.micromark.com)
rethinkinG the MetAl ClAy ■ Stainless steel bolts, threaded rod, nuts
hollow forM (Small Parts Inc., 800.220.4242,
page 34 www.smallparts.com)
■ Metal clay, tools (Rio Grande, ■ Nuts, bolts, washers (Micro Fasteners,
800.545.6566, www.riogrande.com; 800.892.6917, www.microfasteners.com)
Whole Lotta Whimsy,
www.wholelotta
whimsy.com)
34 64
www.ArtJewelryMag.com 79

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