If this works out I may have to try one to. I already have an airplane to put it on. This is way beyond any project I have done to date. I love it, keep up the reports.
Looking good, following along. I'm building an Ohrndorf 5-cyl radial. Quite similar to the Edwards dimensions & overall layout (and my first go at anything this complex). I also broke a tap in my 2024 crankcase size M3, my own fault. The alum solution didn't work well at all. My conclusion on succes related to this is 'it kind of depends'. Mine was a coated tap as opposed to bright HSS which may have had something to do with it. It made a complete mess of the part long before the tap dissolved. Personally I would try & drill past it with a mini annular cutter, tap the hole & insert an aluminum plug permanently with Loctite & go from there. If you want to read about my grizzly details I can link my post over on Home Model Engine Machinist. There have been a few Edwards builds documented there btw if weren't already aware.
Ever since I broke a tap whilst making the Improved chuck for taps I have been thinking of making a simple spark erosion apparatus. When making the hexagonal hole in the mill quill lock lever I again...
What about trying mechanical tap extraction. I have a set of tap extractors with little fingers that slide down the flutes of the tap and let you try to drive it out. Full admission, I have never used them yet, but it seems like it could work in principle.
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