Method for making a dual threaded bolt roll forming die

A method for making a die for roll forming a dual threaded bolt, the die forming method including the steps of:

• identifying a block of die forming material having a substantially flat forming surface between a pair of opposing side edges and opposing lead and rear edges;
• cutting the forming surface with a truncated coarse thread cutter to form upper portions of a series of parallel coarse thread crests;
• further cutting the forming surface with a separate cutter between the upper portions of the series of parallel coarse thread crests to form roots between the coarse thread crests, the roots including bridges therein angled relative to the crests and extending between adjacent crests;
• and
• wherein said cutting step includes using the truncated coarse thread cutter having a circular form with cutting teeth on a perimeter, the cutting teeth having a notch defining two shoulders defining a cutting tip, matching a contour of the upper portions of the coarse thread crests, to form the upper portions of the coarse thread crests.