Shortening SS Screws for windows
Posted: Wed Jul 08, 2020 3:42 pm
Just found this pic I took when doing my windows, so FYI. It’s often a case working on boats and specifically when I was doing my windows that getting an ss screw short enough means going down to a gauge more suited to watch repair than boat repair. Shortening screws can be achieved lots of ways, if only one, pliers and a bench grinder is ok ( not the go holding it with fingers 
unless you have a few spare, fingers that is! ) When I had 4,651 screws less than half an inch long I eventually found the easiest thing was to vice clamp a piece of wood the thickness you need, drill 8 or 10 holes and bung a bunch of screws in said holes with your drill driver.
Then, it’s a simple matter to cut them all off to the exact and same length. I used an angle grinder with a thin kerf cutting blade. These were slightly larger gauge than my original window fasteners so I used one sharp screw to tap the thread before using the blunt ones. I later sealed over the inside with resin to stop any leaks.
unless you have a few spare, fingers that is! ) When I had 4,651 screws less than half an inch long I eventually found the easiest thing was to vice clamp a piece of wood the thickness you need, drill 8 or 10 holes and bung a bunch of screws in said holes with your drill driver. Then, it’s a simple matter to cut them all off to the exact and same length. I used an angle grinder with a thin kerf cutting blade. These were slightly larger gauge than my original window fasteners so I used one sharp screw to tap the thread before using the blunt ones. I later sealed over the inside with resin to stop any leaks.