How to: Shorten Snap Head Screws

Is the snap head screw too long to fit into the receptacle?

In about one in one-hundred aircraft, something may block the full depth of the screw shank from inserting into the receptacle. This may be due to various airframe reasons, including wiring, repairs, or insulation. Whatever the reason, we have a simple way to solve it.

Many people will find they have an electrician tool in the toolbox. One of the many features of this tool is a screw shearing hole intended to shear cleanly the shank of the screw.

You should always use the right tool for the job.

Most electrician tools will have a pair of holes that align. One side is threaded to hold the screw, and the other is sharp to shear the excess shank. Use the appropriate-sized hole (10-32 or 8/32) to cut down the screw to size. Here is a photo courtesy of Home Depot and Klein Tools:

Here are the steps to shear the screw:

If you need, mark the screw shank with a reference line.
Align the shearing holes on the tool.
Thread the screw into the correct hole to the desired length.
Pull the tool handles apart to apply force and shear the screw.
Collect the wasted shank to mitigate FOD.

Here is a video on YouTube:

CAUTION: Use all tools as directed. Use personal protective equipment. Stop at any indication of resistance. Do not install screws if there are visible signs of damage or striping on the receptacle.