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I have a flat bar that needs to be drilled and bolted to a M6 threaded fixing. The angle of the flat bar must be as shown in the photo. The problem is the flat bar does not intersect the threaded fixing at 90 degrees. So drilling the flat bar and bolting it will cause the angle of the flat bar to change. The flat bar needs to be fixed in the position that it is. what is the best way to tackle this? Are there any special washers or anything else that I could use?

I would be grateful if you could have a look at the photo below and let me know your thoughts.

You could try a 2 ½ degree taper washer between the two parts

Or if it is that critical file the end of the hex coupler to match the angle at which the flat bar sits.

Chippo1 wrote: ↑Sun Feb 23, 2020 8:57 am You could try a 2 ½ degree taper washer between the two parts

Thanks for your reply. Do they do taper washers in M6 size? The closest I can find is M8.

these might , looks like a 7mm hole
https://uk.misumi-ec.com/vona2/detail/110300252210/
https://uk.misumi-ec.com/pdf/fa/2014/P2 ... F34_EN.pdf

Thanks for the link, however I think they all look like special order??

Any chance of twisting the end of the bar in a vice with a large adjustable spanner?

The bar is 3mm thick so probably could bend it in a vice, but worried things will turn out a big mangled! I can't really heat it up in situ either, otherwise I would heat it up, hold it straight while bolting it tight, in the hope of deforming it for correct alignment.

File / grind the end of the coupling nut to the correct angle if there's enough give there?

For a taper washer try finding your local industrial fixings supplier , chances are they will just give you one. Last lot I purchased were imperial any way so try searching 1/4” taper washers.

How about two washers with a smear of epoxy in between squeese to the taper you want let it set and drill out any surplus from the centre hole.

toolbox wrote: ↑Sun Feb 23, 2020 2:03 pm How about two washers with a smear of epoxy in between squeese to the taper you want let it set and drill out any surplus from the centre hole.

That's actually quite a good idea. Once it is set, it could even be welded.

toolbox wrote: ↑Sun Feb 23, 2020 11:10 am Any chance of twisting the end of the bar in a vice with a large adjustable spanner?

That's what I ended up doing in the end, even though I was apprehensive. It all worked out well in the end.

Dave54 wrote: ↑Sun Feb 23, 2020 12:10 pm File / grind the end of the coupling nut to the correct angle if there's enough give there?

I ended up bending the bar in the end, but how would you file it to the correct angle? That's okay if you can do it in situ and keep offering the work up to check how you are doing, but there was not enough space to get a file in there.