Rebarreling and Home-Shop Machining

I needed to shorten a small shock a bit for use on a Radio Control car.  I needed to add 4-40 threads to the end of a 1/16 plain shaft on the shock in order to install the plastic shock end.  We mounted a 5/8 inch long 4-40 set screw, which has an Allen head hole already, in a drill chuck installed to the headstock.  We used a Cobalt 1/16 drill bit driven by hand to drill 3/16 into the Allen screw using the Allen hole as a pilot hole.  This went very well.  I then cut the Allen screw ¼ inch long and installed it on the shock shaft end with red LocTite.  The project came out well and should withstand the rigors of racing this car.

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