On Tue, 18 Dec 2007 22:37:45 -0800 (PST), wrote:

Hi all,
I´ve the following situation: 4 mm mild steel plate in which I made 6
mm holes with thread. In these holes I put bolts which I first dipped
in epoxy to fix them in position and seal the thread waterproof. I
screw the bolts in only for the thinkness of the plate, so a large
part of the bolt and head is above the plate. After the epoxy is cured
I cut the bolts with the angle grinder and grind what is left of it
down until it´s surface is flush with the plate. The problem: cutting
the bolt makes it really hot and the epoxy is only capable of
withstanding temperatures up to 150 deg c. Above this it burns and
does not seal anymore. What I tried to do is spray water onto the bolt
while cutting. It seems to keep the proces a lot colder, but also
somehow the cutting becomes slower with the water. Does anyone have a
suggestion how to do the cutting and/or the cooling differently,
better?
greets, Joost Jager

Get block of steel perhaps 50 mm square x 25mm thick. Drill and tap
a hole in the center of the square side.

Screw 6mm allthread thru the block and into the plate so the block is
snug or tight to the plate. Use Loctite rather than epoxy. Keep
Loctite off the block and out of its threads.

Strike block smartly sideways with a maul. This will easily shear
off the 6mm mild steel allthread flush to the plate. Only very
light, if any, grinding will be necessary to make the surface smooth.