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How to Cut Spiral Grooves in Bushings

Bushings are typically made from metal such as aluminum. However, when metal is not available, you can make use of solid surface material used for kitchen countertops. If you require threaded bushings, these must be added after the bushing has been shaped. To do this you will first need to create a blank to make the bushing.

Things You'll Need

1-inch square solid surface material
Felt tip marker
Miter saw
Diamond-tip blade
Drill press
Bench grinder
Bench vise
Tap and die set

Instructions

- 1
  Mark the length of the busing on the 1-inch square piece of the solid surface material, using a felt-tip marker. Repeat this step to mark the number of bushings you want to make.
- 2
  Cut the solid surface material to the required size with the miter saw, using a diamond-tip blade. Repeat this step to cut the remaining bushing blanks from the solid surface material.
- 3
  Secure the cut piece of solid surface material to the drill press. Drill a 1/4-inch hole through the center.
- 4
  Measure the width of a metal bushing, if available, with the caliper. Make a note of the measurement.
- 5
  Grind the square edges of the bushing blanks by using the bench grinder. Continue to grind the sides of the blank until it is round.
- 6
  Mark the diameter location on the blank. Grind the side for the smaller diameter until the correct size is obtained. Secure the finished bushing into the bench vise with the smaller diameter side facing down.
- 7
  Determine the size of die tool needed for the bushing. Attach the die to the tap, and insert the die into the bushing.
- 8
  Turn the die tool 1/4 turn clockwise and then 1/4 turn counterclockwise. Repeat this step until you have threaded the bushing.

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