The Basics of Thread Tapping

[Obi-Dar Ke-Gnomie]

I have gotten away with tapping aluminum in the past without using lubricant, but I think I really should start. An ounce of prevention...

[Skaboom]

First, please forgive my ignorance, I have never tapped a hole before. What kind of lubricant would you guys recommend? I have white lithium grease, would that be ok? I saw someone mentioned alcohol, do you mean like isopropyl alcohol? Thanks guys.

PS: Thanks Lord Maul, this tutorial is a godsend.

[swear000]

oil or wd-40 would probably be ideal. I think the lubricants are more geared toward high speed drill taps. I have done all mine by hand (without lubricant) and they all turned out fine). However, I may be skating on thin ice.

[Arm on Fire]

think of lubricant as an insurance policy. if you dont have it you may regret it, if you have it chances are you will be better off.
In my opinion, WD-40 is good and if easy to find . Personally I think kerosene is the best for aluminim.

[Matt Thorn]

I just noticed that the metric equivalents are all off by one level.

8-32 should be M4x0.7.
6-32 is M3.5 x .06.
10-32 (I'm assuming that's "UNF") is M5 x .08.
4-40 is M3 x .05.

I think these are the thread sizes most commonly used in sabersmithing. Here's a complete chart.

[B5813]

This is an easy one for metrics... to find the right size drill bit for the tap subtract the thread pitch from the screw size. Example: M5 screw with a .7 thread pitch would require a 4.3 drill bit.

[Lord Maul]

The metric list was posted by someone on FX Sabers. I'll update it with yours Matt

[Matt Thorn]

This is an easy one for metrics... to find the right size drill bit for the tap subtract the thread pitch from the screw size. Example: M5 screw with a .7 thread pitch would require a 4.3 drill bit.

Wow. I never noticed that.

The metric list was posted by someone on FX Sabers. I'll update it with yours Matt

Thanks, Lord Maul.

[vsxultra]

I am interested in thread sizes used in the MHS pommels and hilt bodies. Mainly threads per inch. I am attempting to cut threads on my custom hilt and I like the way the MHS hilts are put together. I would like to make my own threads on my custom sabers with exact thread sizes as the ones used in the MHS sabers. If anybody knows the specs, I would be most grateful.

Thanks

VSXUltra

[Matt Thorn]

I am interested in thread sizes used in the MHS pommels and hilt bodies. Mainly threads per inch. I am attempting to cut threads on my custom hilt and I like the way the MHS hilts are put together. I would like to make my own threads on my custom sabers with exact thread sizes as the ones used in the MHS sabers. If anybody knows the specs, I would be most grateful.

Thanks

VSXUltra

That sounds like a major challenge, considering that not even all of TCSS' MHS parts screw together smoothly. I have an MHS saber that is about a quarter of an inch from completion, the quarter of an inch being the last span of thread that is stuck so firmly I can't get it in any farther. To be honest I feel a bit screwed over. (Pun intended.) I know I can send it to TCSS for Tim to fix, but I live in Japan, and there's an Ultrasound 2.0 board in there that can't be removed, so the cost of insured shipping makes that solution pretty unappealing.

But if you do go ahead with your plan, I suggest you give your threads a bit more leeway than those of the MHS parts. These are illuminated sabers were making here, not space shuttles.