Go to Otherpower.com Home Page Go to Forcefield Shopping Cart Go to Wondermagnet.com Home Page
Front Page - [Homebrewed Electricity-- (wind) (solar) (hydro) (steam) (controls) (storage) (mechanical)] - Classifieds - Site News
Everything - Newbies - [Remote Living-- (housing) (heat) (light) (water)] - Rants & Opinion - Diaries - Our Products
LED light for Fiji 2008 Completed | 9 comments (9 topical, 0 editorial)
Re: LED light for Fiji 2008 Completed (3.00 / 0) (#2)
by Sundog on Fri Mar 14th, 2008 at 11:27:24 AM MST
(User Info)

If you have a lathe, preventing breakage of taps is easy-peasy.  If you don't have a lathe, it's nearly as easy.  

With a lathe -

  Grab a piece of 1/2" diameter brass rod about 3" long.  Chuck it up, turn the outside down true.  Now drill a hole about 1.5" deep using a chuck in the tailstock, just a hair larger than the OD of the tap shank.

Use a dremel with a grinding wheel (or a file, if you're a glutton for punishment), to put some flats on the tap, just above the cutting threads.  Make it a size that's easy to grab with either a tap wrench or a small ignition wrench.  

Without a lathe -

Very carefully clamp the brass stock in the mill vice, then drill a hole in the center of it (as close as humanly possible) just a tad larger than the tap shank.  Modify the tap the same as above.  

To use -

Drill your hole using a drill press.  Without moving the workpiece, table, or head, swap the drill bit for the tap holder.  Put the wrench on the tap and slip it into the chuck.  Hand tighten the chuck, then lower the quill, lock it in place, and start tapping!  

For holes to a specific depth, put a set collar on the drill bit shank, set the plunge depth on the drill press, and use the above procedure.  That way when you replace the tap holder with the drill bit, your depth is still correct.  Most blind tapped holes have a bit of fudge factor involved in their depth, anyway.  

The above method sounds like a royal PITA, but in actuality it isn't that bad, and once you get used to it, it becomes very fast.  You tap the holes straight, true, and best of all, you'll rarely break taps anymore.  Unless you get crazy and abuse 'em.  

The above method also works excellent for tapping holes that are drilled at an angle to the surface of the workpiece.  Drill the hole, counterbore, etc, de-burr, then swap in the tap holder and tap it before you change the position of the workpiece or head.  Works like a champ every time.  

Just my $.0134 (damn recession!)

Shad H.




Re: LED light for Fiji 2008 Completed (3.00 / 0) (#5)
by richhagen (richhagen (a t) Juno.com) on Sat Mar 15th, 2008 at 12:51:20 PM MST
(User Info)

I might try something similar for my mini milling machine.  That way I could drill all of the holes in one step, and then change out for the tap holder design.  The machine would then line up the tap over each hole through the code, and I could pause it at each for tapping.  

I did manage an average of 84 tapped holes per broken tap, so it added about 6 cents per hole tapped for the costs of the taps that I broke, and about $20 to the project costs, so reducing that would make a difference.  Rich
'A Joule saved is a Joule made'
[ Parent ]



LED light for Fiji 2008 Completed | 9 comments (9 topical, 0 editorial)

Menu
· create account
· How to use the board
· FAQs
· search the board
· Google search the board
· Old Otherpower Board

Login
Make a new account
Username:
Password:

Powered by Scoop
You must be a registered user to post here. It's easy and free, and the link is on the upper right side of your page.
All trademarks and copyrights on this page are owned by their respective companies. Postings are owned by the poster, but may be deleted or moved at the ADMIN's sole discretion. The Rest © 2003 Forcefield.
You can Email the board ADMIN here. PLEASE include the username you signed up with!