You will be mortified by the cost of 2.25" bolts and all that machining.
Then you'd have to trim off the hex head.
It would be a lot cheaper to buy barstock and drill and tap it for his
existing bolts.
But that tap is unusual and hard to use, so maybe using longer stock and
threading the top part on a lathe would be the more economical solution.
You don't have an expensive anchor, so the epoxy would still be needed.
Come to think of it, how about just making a 2.25" bushing, through which he
puts the original size bolt??
While it's in the lathe, cut aggressive grooves around the outside for lock
in of the epoxy. Cheapest solution...mild steel or stainless fine, possibly
from salvage, and minimal skill level.
Even I could do it!
I'd also run a weld bead around the top and bottom of the bushing, where the
bolt goes through, to guarantee no movement that could fatigue the epoxy.
He could machine the hole a hair undersize and do a shrink/press fit to the
bolt, but this can be tedious and would add to shop time.
Now that I finally got outside the box, consider a stack of washers, rather
than the bushing.
If he gets washers of two different ODs, they will provide the grooves!
Run a nut down hard on the stack and it's rigid!
WL
-----Original Message-----
From: towertalk-request@contesting.com
Sent: Wednesday, October 15, 2014 12:00 PM
To: towertalk@contesting.com
Subject: TowerTalk Digest, Vol 142, Issue 27
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Today's Topics:
1. Re: Anchor Bolt Material (Jon Pearl - W4ABC)
----------------------------------------------------------------------
Message: 1
Date: Wed, 15 Oct 2014 11:30:41 -0400
From: Jon Pearl - W4ABC <jonpearl@tampabay.rr.com>
To: TexasRF@aol.com, towertalk@contesting.com
Subject: Re: [TowerTalk] Anchor Bolt Material
Message-ID: <543E9321.5060101@tampabay.rr.com>
Content-Type: text/plain; charset=ISO-8859-1; format=flowed
That's exactly what I was thinking, Gerald.
Marvin's greatest constraint is an oversized hole. I would make a trip
to a machine shop with some appropriate sized anchor bolts and and have
the upper threaded portion necked-down!
73,
Jon Pearl - W4ABC
www.w4abc.com
On 10/15/2014 8:03 AM, TexasRF--- via TowerTalk wrote:
How about larger anchor bolts with upper six inches or so machined to fit
the base holes?
Could the base holes be reamed to a larger size?
K5GW
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