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most dismal event ever

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bbaley

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#1
I have had daughters shack up with less than desirable marriage opportunities,
bounced checks at the bank,
not got hired for a job I was over qualified for,
missed a target at 50 yards,
forgot to put coffee pot under coffee maker,

but nothing I can think of right now is worse than breaking off a 6-32 tap in a project piece that is the last of 6 holes on a project that is 99% done.

man oh man.
 

MrWhoopee

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#2
I feel your pain. Forty years ago I was making a set of collet blocks in my machine shop class. I broke a small tap off while tapping a set-screw hole in the hex block. Never got it out, so it never got finish ground. It's still in my toolbox.
 

benmychree

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#3
We all have our cross(es) to bear ---- I was lucky to have a friend with an EDM machine.
 

Martin W

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#4
There is a bright side. It could have been a #4-40 tap!
I Feel your pain.
Cheers
Martin
 

Rooster

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#5
It's not a problem, just a need for a solution. I had the same problem, ordered a solid carbide ball end-mill and drilled it out. For the size you broke perhaps a 5/64. Good luck.
 

Bob Korves

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#6
A 6-32 tap is the worst possible tap in the imperial system. Root diameter as a percentage of total diameter is a big difference, which gives it more chance of breaking than any other standard tap. Poor design, but a common standard size. I knew that going in, and have never broken one (so far). Just posting this has probably broken my run of luck... ;)
 

mmcmdl

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#7
Carbide ball end mill , plunge thru it and plug . No sweat . I thought this thread might be about my work night tonight , I had t:)o look .
 

bakrch

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#8
I recently tapped a few 3-56 holes, and all I could think was "well, at least it's not 6-32!"
 

projectnut

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#9
There is a bright side. It could have been a #4-40 tap!
I Feel your pain.
Cheers
Martin
The company I worked for designed and built it's own processing and packaging machinery. One of our projects was a machine with 136 to 150 individual molds (depending on the product to be packaged) for forming plastic. Each "platter" had 12, 4-40 screws holding film guides in place. I can't tell you how happy the guy was that drew the straw to drill and tap all 1,800 of them.
 

Suzuki4evr

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#10
W
I have had daughters shack up with less than desirable marriage opportunities,
bounced checks at the bank,
not got hired for a job I was over qualified for,
missed a target at 50 yards,
forgot to put coffee pot under coffee maker,

but nothing I can think of right now is worse than breaking off a 6-32 tap in a project piece that is the last of 6 holes on a project that is 99% done.

man oh man.
Wow that's something to scream about
:chemist::sorry::headache::***** slap:
 

BROCKWOOD

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#11
I feel your pain on this. In a former life, I loaned out tools. On 2 occasions my torque wrench came back broken. The 2nd time, I got in a hurry & promptly broke 2 rocker studs while getting a friend's truck tuned. Having to scramble for a permanent fix pronto that day broke me of tool loaning. Now: You can borrow any tool I have BUT I'm operating it!
 

Mitch Alsup

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#12
If the part is aluminum, you can use a hot solution of saturated alum to eat the tap out of the hole and leave the aluminum unmolested.
If it is steel, you are out of chemical luck.
 

markba633csi

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#13
Yep, I hate 6-32 also, for the same reasons. The thread is just too coarse for the diameter. I studiously avoid putting them in my designs. They are also real easy to cross-thread when the hole gets worn. 8-32, 10-32, no problem. I do like 4-40 though for some things
The stupid US electrical system uses 6-32 everywhere! Ugg
 

MrWhoopee

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#14
As a slightly related aside, the distributors in the old Honda D15 and D16 motors use a screw to secure the rotor to the shaft. It is officially designated as an M3.5 x .8, which is a very non-standard screw. I was looking for some socket head cap screws to fit, doing some very strenuous mental math while standing in the fastener aisle at Orchard Supply Hardware. I already knew that .8 mm pitch was nearly identical to 32 tpi. Calculating 3.5 x .04 (actually .03937), I came up with .140 in., and the light came on. They had used a 6-32 screw and just converted the dimensions to the closest metric equivalent. I've never found out why they would do such a ridiculous thing.
 

middle.road

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#15
#2-56 in SS, 4th hole out of (4).
 

Mitch Alsup

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#16
In my past, I have buggered up a hole with a tap. Before I learned the alum trick, I would use a diamond bit under water and slowly grind the tap away. I generally had to drill the hole larger and swage in a plug that could be drilled and tapped.
 

savarin

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#17

bbaley

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#18
Carbide ball end mill , plunge thru it and plug . No sweat . I thought this thread might be about my work night tonight , I had t:)o look .
Ok I should try that!
I think I might have enough room to move up to a #8 if a have to
 

bbaley

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#19
Yep, I hate 6-32 also, for the same reasons. The thread is just too coarse for the diameter. I studiously avoid putting them in my designs. They are also real easy to cross-thread when the hole gets worn. 8-32, 10-32, no problem. I do like 4-40 though for some things
The stupid US electrical system uses 6-32 everywhere! Ugg
I'll keep this 6-32 issue in mind.
The sad part is I have 3-4 million of the little buggers around in every size imaginable so it makes it hard to not use them.
 

bbaley

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#20
We all have our cross(es) to bear ---- I was lucky to have a friend with an EDM machine.
apologies for my density - but what/how/why the EDM ?
 

Hawkeye

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#21
Electric Discharge Machine. It uses a stream of tiny sparks in a liquid bath to eat out the piece it contacts.
 

markba633csi

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#22
Also called a Die Sinking machine I think
 

NortonDommi

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#23
I hope you manage to get it out. One thing to think about with small taps is that when they wear the drag on then rises exponentially as edges dull.
Small taps are cheap and as some as they get worn chuck them in a separate container for use in cleaning dirty threads. I'm slowly replacing my taps as they wear out with Serial Taps wherever possible because of the extra strength and better finish. I am also of the opinion the cheap taps like cheap drill bits are very expensive.
As a broke person I often have to buy cheap to do a job but with things like drill bits and taps replace with the best you can get. Over time you end up with very good quality in all the important ones.
These are my preferred brand of taps: https://www.voelkel-shop.com/en/voelkel.html
 

NortonDommi

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#24

bbaley

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#25
Here's the page with 6-32. https://www.voelkel-shop.com/en/hand-taps-set-of-3-pcs-din-352-hss-g-unc.html Expensive but worth every cent. Question do you use a tapping machine or a guide block? I have nerve damage and have to be very careful when working especially with things that can break easily if flexed in use.
Thanks for the tap info!

Usually I use a Brown & Sharpe Tap follower (spring loaded)in the mill or drill press or lather - along with whatever tap handle I am using.
And that works pretty well for me.

On the small tap "T" wrenches I made some wooden handles to make them easier to hold because I have found that when I am tapping a lot, my fingers get sore, and that gets me in a hurry to get done, and well, you see the result of that :)

The wooden handles also let the use my fingers (e.g one finger and thumb on each bar of the handle) using small taps which usually feels like it keeps me from putting too much pressure on them.
Obviously this time I was either tired, in a hurry or pick an excuse.

What I really want to find are some quality tap "T" wrenches for the small taps.
either that or some small taps that have a hole in the end that allow for use of a follower.

Some of my better quality larger taps have follower holes, but none of the smallest ones (maybe that''s just the norm) so leaves me with the "T" wrench handle option until I find a better solution.

I don't have any fancy power tapping heads or anything like that. I've used the drill press to power tap thin plate steel, but that's about as adventurous as I've got along those lines.

And I use copious amounts of Tap Magic, although I don't have any of the aluminum variety yet.
 

bbaley

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#26
I hope you manage to get it out. One thing to think about with small taps is that when they wear the drag on then rises exponentially as edges dull.
Small taps are cheap and as some as they get worn chuck them in a separate container for use in cleaning dirty threads. I'm slowly replacing my taps as they wear out with Serial Taps wherever possible because of the extra strength and better finish. I am also of the opinion the cheap taps like cheap drill bits are very expensive.
As a broke person I often have to buy cheap to do a job but with things like drill bits and taps replace with the best you can get. Over time you end up with very good quality in all the important ones.
These are my preferred brand of taps: https://www.voelkel-shop.com/en/voelkel.html
Those threading tool holders on the Volkel site look like the stuff !
 

westerner

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#27
Just posting this has probably broken my run of luck...
And with that, I will withdraw any observation or advice I had planned to offer:confused 3:
 

NortonDommi

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#28
Those threading tool holders on the Volkel site look like the stuff !
All I can say is that I am impressed with the quality and the difference between using a good tap and a mediocre one is very noticeable. Threading stuff is all Volkel do so I am assuming they know what they are doing. Might be worthwhile seeing if there is an agent near you. I'm on the other end of the world and the guy I buy off is on the other main Island but has good stock at very reasonable prices. If he doesn't have something he will get it in 3 days and I have also bought direct from Volkel and it has taken about 4-5 days to my door, service is excellent.
 
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