The first item I made for this project was a pair of guide blocks to hold the threaded rod stock with. I made mine uniform, and square, then drilled holes out of the center of each. I used some phenolic cellulose material I had on hand, I am sure other materials are equally as suitable to use.
Step 2: Add Set Screws to Guide Blocks
I want my guide blocks to remain fixed on my threaded rod stock so I tapped holes for set screws into the sides of them. I took this picture at the end just so I would have an image for this step. That is why one block is already cut in half in it. I'll be getting to that shortly. Tap your blocks now. The set screws you use must be flush below the block faces when tightened onto your rod stock.
Step 3: Machine One Block as the Front Half Block
The front block will need to be partially cut away to allow access for grinding to take place on the threaded rod material. I chose to perform this step on my table saw with a fence and the blade tipped to 45 degrees. I'm sure other methods would be equally as effective. This image was staged after the project was completed just so I had a picture to include for this article. It is probably a good idea to perform this operation with the set screws removed if you are going to use a power tool.
Step 4: Prepare Threaded Rod Stock
Taps have a lead in chamfer on the end of them to help get the tap started. I ground mine by chucking the rod into a cordless drill then running it on a belt sander. When doing this it helps to feed into the motion of the machine. Doing so draws the work into the tool and yields more even results with less skipping of the workpiece. I'll draw a simple graphic to explain.