delrin vs aluminum

Especially if it gets wet. I just tried to get an aluminum and stainless roof rack apart after years of use. I had to cut it apart. Perhaps consider anti seize compound?
Robert
Yes when i used to build ally ships we used to smear durolac between the aluminum hull and any stainless fittings coming into contact.

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Just to add that most of the times when I broke a tap it was because I most likely was not holding the tap perfectly straight and level while turning the tap. In other words, I was not just turning the tap but also putting too much side forces on the tap while turning the tap.
That is why these work very well.

http://www.grizzly.com/products/Hand-Tapping-Machine/G8748?utm_campaign=zPage&utm_source=grizzly.com

But...if you want to save some money, here is a good YouTube Video by Tinker John.

His ingenious design uses a Briggs & Stratton connecting rod. I built one similar to his but I have since modified my build by just using 3/8"-drive tap drive sockets and I use a 3/8" long extension which tightly fits through the connecting rod. No drill chuck and an easier build. It works great and I haven't broken a tap since using this fixture.

Hanson® 2 Piece Adjustable Tap Socket Kit https://www.amazon.com/Hanson-3095001-2-Piece-Adjustable-Socket/dp/B000TGM7HY
 
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You can massively reduce your chances of breaking taps by using a drill which gives less than a 100% thread.
 
You can massively reduce your chances of breaking taps by using a drill which gives less than a 100% thread.
I totally agree Magicniner. I'm only pointing out that on those little taps...the few times I broke them I really did not have much resistance turning the tap. In fact, it seemed to be going in rather easy and then all of a sudden it snapped. And I remember that I had carelesly allowed the turning force to move sideways.
I'm pretty sure that since they are so brittle that the side forces increase the possibility of snapping them. That's why drill presses, mills or even a tapping fixtures are much less likely tox break a tap.
 
One of the epiphanies I recently had was tapping aluminum with two flute taps. I always used the "standard" 3 flute tap until coming across a bunch of two flute taps. After using two flute taps, the difference between the 3 flute and 2 flute was astounding. Maybe all you guys knew that already but it was quite an eye opener for me.
 
Two flute taps are wonderful, but should not be used for hand tapping, that is without a fixture or machine spindle to guide the tap; they have little .lateral strength and will snap off easily with small amount lateral force.
 
I totally agree Magicniner. I'm only pointing out that on those little taps...the few times I broke them I really did not have much resistance turning the tap. In fact, it seemed to be going in rather easy and then all of a sudden it snapped. And I remember that I had carelesly allowed the turning force to move sideways.
I'm pretty sure that since they are so brittle that the side forces increase the possibility of snapping them. That's why drill presses, mills or even a tapping fixtures are much less likely tox break a tap.

I totally agree Tim9, I was only adding information not already in the thread without quoting or commenting on any content already there.
 
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