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This seems like such a simple thing yet I can't do it.

I am trying to put hex bolts on my models, but no matter what I do I can't cut them straight.

I end up having to glue them on longer than I need, then carefully sand them down. It's really quite annoying as I would just like to be able to slice off a perfect 1mm bolt top, glue and go.

Any ideas how I can achieve this?

Try taking a new scalpel, and pressing it gently onto a tube/rod whilst carefully rolling it across a flat cutting matt. As long as you keep the blade perpendicular to the tube/rod, you should make a straight cut from the circumference into the centre.

You could file it level afterwards.

Thanks for the replies.

I tried the turny mcrolly technique with tubes and found it slightly hard to line up, I'll try it again. Do you gunk there is a way to make or buy a 90degree cutter?

King, I have used both a file and sandpaper, but I find the results to be inconsistent.

You could rig up some sort of guillotine cutter with a 1mm stop, but I imagine it'd be a very fiddly build and not all that impressive on the production side. Slicing rod is definitely doable (and cleanly) - you may have better luck after a bit more practice. I'd suggest trying, at least (another inch or so of rod can't hurt, right?).

If you really aren't satisfied, have you thought about buying bolt/rivet sheets? Modeling suppliers often sell sheets of them. You just grab a knife, slice on off the backing, and glue it down. It's a pricier option, but much more reliable if you really can't make the DIY methods work.

90° cutters are probably available, and I could rig one up with my old Legos and some rubber bands. Though years of practice have left me confident with the rolling technique, so it's not a necessity for me.

Google 'The Chopper' cutting table...

Otherwise, for the rolly technique to work, use a sharp scalpel and a cutting mat with a grid marked on it.

Line the rod up along a horizontal line on the mat. Then line the scalpel up on your cutting mark level with a vertical line on the mat. That way, as you roll the blade forwards, you can see if you're going straight.

Don't try to cut through in one go, particularly with thicker rod. Once you have a score around the rod, the blade will follow it, and you can take your time with it.

You could also try something simple like putting a nail into a board and using the nail as a cutting guide. Press the flat of the blade against the nail and push away from you. Obviously the rod to be cut is held at the base of the nail.

You could use a Mitre Block and razor saw to achieve that. I have a plastic one and its not quite as snug on the saw as you might want when trying to be accurate, but if you do it carefullly you should be able to do it no problem.

Heres an ali one;

Just smooth the end of the rod before cutting so that it is ready to go on. Saw the rod to the required depth. stick the sawn side down leaving the finished side up.

Smooth the rod again, rinse and repeat.

What generally do that works well, is score the top, and snap it like plasticard. Seems to work well.