I cant win..... :(

[CGompertz09]

Just venting. Here I was doing the last few tasks for completing my saber, and I break the main AV switch. Not a huge loss I figured, just order a new one and good to go. Now today I'm drilling a new hole for the blade set screw, as when the LED was installed, the emitter didn't line up the same way and the current set screw hole ended up behind the shroud. Drill the hole, no issues. Go to thread said new hole.... and the damn thread tap breaks off in the hole nearly flush, nothing to grab onto to try and twist it back out. Tried to drill it out with the strongest metal bits I have, they just skip over and hit the aluminum. And of course, the emitter is currently out of stock in the shop....... In the words of several Star Wars characters. "NOOOOOOOOOOOO!"

[mrknify]

ouch, that sucks, could you get it our with a center punch (while wreaking your threads) or a..... forget the name its a removal tool, has tines that go around the tap, my shop has a couple sets.... i can find out what they are called, i'll also include a picture, on monday though.

[CGompertz09]

Tried a center punch, didn't work. It seems like it somehow seized when I was threading it. Not exactly sure how though. There was only the normal tension when threading, then suddenly stopped and snapped.

[Darth Odious]

Got any pictures? If it's flush with the top of the drilled hole (nothing inside where the blade goes) depending on the blade holder, would it be possible to rotate your shroud to cover up that bad hole, and make a clean one?

[174fps]

Sounds like a job for an EZ out screw extractor.

Best of luck in getting it out!

[CGompertz09]

Rotating the shroud is out of the question. The holes for the switches and for the screws that hold the shroud in place would be left uncovered, and that would just look horrible. To keep things looking as nice as possible, I'm just going to wait until the blade holder is back in stock and get a new one.

[mrknify]

Sounds like a job for an EZ out screw extractor.

Best of luck in getting it out!

thats the one!¡ they are awesome

[Boj-Vaati Mau]

Were you backing the tap off during the process? If not, that's what probably did it. Backing it off takes the tension off that's produced from the shavings building up during taping.

[brett]

I feel for you mate. Very frustrating. The only consolation i could offer is at least you CAN buy a new part, not like it is a 70 year old, rare, Graflex, or some other part costing hundreds. Good luck on your next attempt.

[cardcollector]

I had a saber like that. A huge money pit where things kept going wrong. It happens to all of us at one point in time. Take a break, get some new parts and tools, and begin again.

As far as the tap breaking, if you aren't using oil with your tap, you might want to do that. I don't use it with smaller taps like 4-40 or 6-32... but with 8-32+ it is a must I have found for reliable and clean threads.