[samualt]

I got 32 taps to do at 5/16-18 for my TSlots legs. Then I have another 24 at least for other parts. Doing this by hand is taking forever. I tried using a little oil. It does seem to help a little.

Any other tips?

On the upside, it's a no-brainer. So I can just sit in the garage during the sweltering heat and think of happier days while I work. LOL.

[duluthboat]

That's why they call it work.

I find that WD40 is a good tapping fluid for aluminum.

Gary

[IJ.]

I think if I faced that job I'd take the time to make a jig that would start the tap square and use a cordless drill with the clutch set light to do the job.

[Cold Fusion]

Get some WD40 and a long movie.

[buscht]

I agree with using a cordless drill, preferably one with a clutch. You would be done in an hour or so if you are careful

[ty1295]

Spiral taps and proper thread cutting fluid.

Makes all the difference in the world. Makes WD40 and old standard taps seem like water in comparison.

I only buy spiral now myself. big difference.

[dmgdesigns]

TAPMATIC!! Great tapping fluid. No sticking. No breaking. Like screwing a nut on a bolt. Get the kind for Alu.

[High Seas]

Just guessing -- you want a cleaner look than using the 90 degree angle brackets they make? I admit that gear can be a bit pricy - with all the screws, and bits, BUT - you have nearly infinate adjustment range in all three axes - and you can use those to help square the rig too. On the other hand, I did some of that "Work-stuff" too so I could mount end fittings for motors, etc - tapped using WD-40.

If it moves and shouldn't - Duct Tape it . If it should and it don't - WD40!
Cheers - Jim

[TAB]

Buy good taps. If the ones you are using came with that tap wrench then you sould invest in better quality. I would suggest two fluters that is what I use when I need to tap 80/20 at work.

I aplogise for ragging on your tap wrench but it looks like the kind you get in the cheap Chinese import tap kits and I know those taps are lousy at best.

[samualt]

TAB:
"...it looks like the kind you get in the cheap Chinese import tap kits..."
I'm so embarrassed! LOL. Yes, the handle is from a cheap chinese import tap kit (ala Harbour Freight). The tap is from the local hardware store because the kit didn't have what I wanted in it. I think the tap is name brand.

[strat]

when i'm tapping metal i use a mix of beeswax and kerosene works really good

[signIT]

Have you tried selftapping screws, same as the industries uses I have seen it in Hewlett Packard instruments and some japaneese euqipment they often use it when aluminium profiles is used.

[trubleshtr]

I use the drill to tap aluminum profile and cutting fluid. If I am in a hurry I'll just use the screw (bolt) itself, this works well when using BOSCH extrusion. Theire profiles are metric though, and I tap either 10 mm or 12mm depending on the profile. If what you are using is standard in diameter (mount holes) just run the 5/16 bolt into the hole with a socket head drive attached to your drill..............

[windsor]

I was at the local 80/20 supplier a while back and saw a neat gizmo that they had for tapping the extrusions . it was a piece of extrusion with the umhv pads to hold the extrusion to be tapped , and a die grinder held on its side in a jig to run a spiral tap .-----looked pretty slick , but at $2.00 a hole for the tapping service I opted for the hand method . --I did find it helped to bevel the holes with a countersink before starting the tap .

[samualt]

Well, my arm was so sore today I had to let it rest. Between the 20 taps I did and working on a pickup I pulled a shoulder muscle pretty good. I took this small reprieve to go and buy a cordless drill: Coleman, 24 torque ranges, variable speed forward and variable speed reverse, 18 Volt. Plus, I got some hex-bits so I can assemble my machine with the drill (Tslot bolts have hex slotted heads). Now I'm as charged up as my new drill !

High Seas:
On some pieces I'm using internal attachments, some the external butt-joints, and still others are getting the brackets. I have a hodgepodge of hardware to mount it all. For the feet I had to make my own base plates and thus tap all the leg bottoms.

[signIT]

Hi,

Look at this before you go on with your DIY tapping boring work, http://www.brycefastener.com/catalog.pdf
They have self tapping machine screws and they are just so... yes yes!

[samualt]

To all the people who have used Taps in their cordless drills:

How are you supposed to mount the Tap when it has a 4 sided end and drill-bits/drills use 3 sided ends? Drills have three pinchers on the chuck, not four. A four sided Tap ain't going to mount properly. It will wobble. I guess I'll go to the hardware store to see if they have an adapter, I kinda doubt it. All the Taps I own have four sided ends. All the Taps I have seen have four sided ends.

So what am I missing?

[IJ.]

Samult: I just slip the shank into the chuck !

If you have problems snapping taps you can try a 2 flute gun tap as they're a bit stronger.(at the least try to stay away from taps with a relief under the tap flutes)

[buscht]

Samualt, yes, don't just grip the 4 sided end, but grip the round shank, just like a drill bit.

[samualt]

"yes, don't just grip the 4 sided end, but grip the round shank, just like a drill bit"

The problem with that is it slips. You have three pinchers trying to tighten on a machined smooth round neck. It's trying to impart some torque, but then the Tap just starts slipping in the chuck. Hmmm....
I did lightly cut some striations on the smooth round neck of the Tap with a dremal cutting blade, that helped the chuck grip the Tap a little better. But even that slips.

You simply can't get there from here.
1. Perhaps because my cordless drill has a keyless-chuck it won't tighten down enough.
2. Prehaps I'm trying to use a cordless drill on too large of a tap. I'm trying to use a 5/16-18 tap. Maybe it is just to big of a cutting area.
3. Perhaps my drill isn't strong enough because the one time it didn't slip it didn't cut very far at all before bogging down.

I have no problems doing it manually. So I guess I have a few days of hand tapping still to do............arggghh!