The way I shorten screws - Model Railroader Magazine

I think we are talking about machine screws, not wood or metal screws.

I've used several methods over the years.

My preferred is to use my Super Champ (Amp Incorporate Harrisburg, Pa) wire strippers. Mine handles 4-40 through 10-24.  I've two of them, had them 25 or 30 years I suppose, and I know they have been around for 40 or more years.  Only trick to them is having the right size screw and screwing the screw in from the correct side.  Screw in so the keeper part of the screw is inside the threaded die of the tool.  It just works.  I've seen cheap dollar bin crimpers with the cutters and they were worthless. 

 For all others, I use the nut technique already listed and like others, I try to use two of the correct sized nuts with the nuts on the keeper side of the screw.  Cutting with a die grinder or dremel is preferred by me, because one can get such a clean cut.

I also have a set of thread chasers that I use for 1/4" - 1/2" bolts. Cut the bolt with die grinder and use the thread chaser to clean up the threads.  If one has problems getting the bolt or screw to mate with a nut properly, I use a bench grinder with a fine stone or my belt sander to put a slight taper on the end of the threads.

I've never been real successful using dikes or cutters of any kind.  Too much thread damage.

My 2 cents worth nothing more,

Joe