The Basics of Thread Tapping

[J-Saber33]

I definitely agree with Rathan and Nachttoter, a center drill is considered a good machining practice when drilling any hole. Particularly when the hole is at the top center of a cylinder such as a saber hilt or blade holder. Even a new or sharpened twist drill can wander when brought into contact with the piece being drilled. The center drill provides a starting point for the drill to bite into the material. However, finding center drills in your local hardware stores may be difficult. In a pinch, you may use a punch to make a starting place, just be gentle with the aluminum. As for tapmagic, it is what the name says: MAGIC! Not that saber building involves many hard materials, but I've tapped some deep, blind holes in things like stainless and tapmagic makes all the difference. Having said that, a little bit goes a long way when tapping a small hole. You only need enough to coat the tap and preserve the cutting edge. It will also help metal chips cling to the shallows of the tap rather than becoming gummed up in the hole. I mention using a small amount because it can really make an oily mess of your part.

[ilpostino]

Which of the screws 8-32 x 3/8" Stainless Steel thumb screw and 8-32 x 1/2" thumb screw fits with the 8-32 Tap & drill set and/or 10-32 Tap & drill set? (If they dont fit - what do I need to which?

[Silver Serpent]

Any 8-32 screw will fit in a hole made by the 8-32 tap and drill set.

[ilpostino]

Any 8-32 screw will fit in a hole made by the 8-32 tap and drill set.

Is the difference between 3/8" and 1/2" that small? (I am from Norway and not used to the imperial units).

[Silver Serpent]

3/8" is 0.9525 cm. 1/2" is 1.27 cm.

If you get a screw that is too long, you can always file it down until it is the proper length. You can't stretch a screw that is too short.

[ilpostino]

So 3/8" and 1/2" is the length of the screw and not the widt?

[Forgetful Jedi Knight]

So 3/8" and 1/2" is the length of the screw and not the widt?

That is correct.

[ilpostino]

Neat. So what is the difference between the 8-32 Tap & drill set and 10-32 Tap & drill set?

[xl97]

the 10-32 will be bigger (width wise)

[Forgetful Jedi Knight]

Neat. So what is the difference between the 8-32 Tap & drill set and 10-32 Tap & drill set?

Those refer to the "width" of the screw (simplistically speaking). 8-32 taps are used for 8-32 sized screws, and 10-32 taps are used for 10-32 sized screws.