Relative Something

We were moving our gas grill off the deck when one of the doors fell to the ground. Cyndie found a bolt with a nut on it lying there, but I couldn’t figure out what had broken or how it had been attached. As far as I could tell, the bolt was just functioning as a post that the door pivoted on. First impression was that a new bolt would solve the problem, but I knew it was more complicated than that.

There wasn’t a way to screw a replacement bolt back on, so the trick would be to mount the bolt in a way that would leave just the threaded portion exposed to mate with the hole in the bottom corner of the door.

Based on the space I was working with, it would likely require a very thin nut. One possibility would be to grind down a standard-width nut to something much skinnier, but I had another idea.

I found a washer with a center hole one size smaller than the replacement 1/4-20 bolt I was going to use. I planned to try tapping threads into that washer. My first challenge was how to hold that little washer in order to cut threads into it.

After a couple of failed attempts to clamp it directly into a bench vise, I pinched the edge of the washer with a vise-grip pliers and then clamped the pliers into the bench vise. The little washer was just thick enough to accept a fraction of threads, and that proved to be enough to spin it on the bolt.

I don’t know if you were able to follow all that, but in the accompanying photo, the little washer I tapped is directly between the bottom of the door and the brown portion of the grill frame. Somewhat to my surprise, it worked to hold the bolt that is coming from below to protrude up into the door.

That’s all I needed. Color me chuffed. I had paused mowing to help move things back onto the deck and then ran into this nuisance of a task. My goal was to find a quick fix and get back to mowing. Given all the steps I ended up taking, it was quick enough and successful enough, and gave me a boost of satisfaction that my ingenuity produced a custom solution that worked on the first try.

The experience acquired from a career in manufacturing continues to pay dividends in my retirement. I bought us a little more time with that old grill, but its days are numbered. It is admittedly well beyond its “Best If Used By” date.

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