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  #21  
Old 01-15-2019, 12:52 PM
Stoo Stoo is offline
 
Join Date: May 2006
Location: LL10, Naperville, IL.
Posts: 60
Default Get Spiral Point Taps

Spiral point taps work best because chips are pushed out ahead of the tap rather than filling up the flutes and causing binding.

Stewart Willoughby, 6 paint is next.
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  #22  
Old 01-15-2019, 04:30 PM
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Erimo Erimo is offline
 
Join Date: Jul 2015
Location: Marcoussis, France
Posts: 111
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Quote:
Originally Posted by jfisher View Post
Major bummer tonight.

Step 4 of 38-03 calls for tapping 6-32 threads through the rear window into the rollbar. Going well until number 8 when I managed to snap off the tap. RRRR!

Not a happy camper. Been reading lots of google searches, but can't find anything that would work with plexi on top of aluminum.

The tap is broken flush with the top of the plexi about halfway down.

Couldn't find anything in the forums for broken taps. Anybody got any ideas??

I'm stuck.
Mine :



With the other tap's end, a 8-32 nut and three little bits of piano string:





and it came out slowly. (Don't forget some cutting oil)
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RV 14A - #140252 - Flying
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  #23  
Old 01-15-2019, 04:35 PM
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JonJay JonJay is offline
 
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Location: Battleground
Posts: 4,198
Default

Looks like a cheap o three flute tap ?
If there is a lesson to be learned here.....
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  #24  
Old 01-15-2019, 04:40 PM
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catmandu catmandu is offline
 
Join Date: Dec 2005
Posts: 792
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Well, I'll vote for a lesson to be learned: by me! Cheapo tap or not, that is one goodly tool to put in my noggin' bag, time to invest in some piano wire of varying diameters. Thanks!
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  #25  
Old 01-15-2019, 07:41 PM
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scard scard is offline
 
Join Date: Jun 2005
Location: Cedar Park, TX
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Quote:
Originally Posted by Erimo View Post
Mine :

and it came out slowly. (Don't forget some cutting oil)
You sir know the art to pause and think . Good show!
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CQ Headset by Card Machine Works
RV-9A N4822C flying 2000+hrs. / Cedar Park, TX
RV8 Building - fuselage / showplanes canopy (Done!)
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  #26  
Old 01-16-2019, 01:52 PM
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Erimo Erimo is offline
 
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Quote:
Originally Posted by JonJay View Post
Looks like a cheap o three flute tap ?
If there is a lesson to be learned here.....
Not so cheap yet !
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  #27  
Old 04-15-2019, 07:17 PM
mountainride mountainride is offline
 
Join Date: Jan 2018
Location: Golden, Colorado
Posts: 34
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Add me to the broken Tap in the rollbar club. Wish I had used a higher quality tap and been more careful. 4 inch crack running back that I stop drilled. I am going to trying gluing it with Weldon #3 I guess. I wouldn't recommend tapping through the canopy, its just too risky and multiple people have messed it up. I would spend the time being careful keeping the tap straight or building a jig for it after #36 holes are drilled. I am a bit devastated and now need to decide what to do on my special order rear canopy. If I get a replacement canopy will I be able to line up the holes well enough without ruining the threads to get a good fitment? Who knows.

-Jason
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  #28  
Old 04-15-2019, 07:29 PM
molson309 molson309 is offline
 
Join Date: Jul 2009
Location: Longmont, CO
Posts: 236
Default

There's something about 6-32 that causes both taps and screws to break, especially 6-32 into aluminum. Because of this I avoid 6-32 like the plague, and use 8-32 as a substitute if it's at all possible.

Even 4-40 taps/screws seem like they hold up better than 6-32.
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  #29  
Old 04-16-2019, 05:25 AM
MED MED is offline
 
Join Date: Jul 2015
Location: Aiken, SC
Posts: 428
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Quote:
Originally Posted by mountainride View Post
. If I get a replacement canopy will I be able to line up the holes well enough without ruining the threads to get a good fitment? Who knows.

-Jason
It is possible to replace the rear glass after cracking it. Not cheap, but doable. Ask me how I know. . A bigger concern to me than the rollbar holes was aligning with the larger dimpled holes in the fuselage. I made up a special jig to be sure I hit the center of each hole when I drilled the window. Good luck.

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Last edited by MED : 04-16-2019 at 05:34 AM.
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  #30  
Old 04-16-2019, 05:27 AM
mountainride mountainride is offline
 
Join Date: Jan 2018
Location: Golden, Colorado
Posts: 34
Default My fix

I am going to order a new rear window. It will be easy enough to install as the last item. There is no way I could stomach installing the cracked window. If I get the same crack after 100 hours of flying I am sure it would be a different story and I would just stop drill, glue and fly on, but not for an initial install.

My tentative plan for a fix is to drill the #36 holes in the rollbar to #30, countersink and plug with a CS4 Rivet. I will drill new pilot holes #52 or smaller in the roll bar between the existing sets. This will allow me to get correct edge distance on my screws and install like normal. I think if I tried to match drill the new canopy into the existing holes I could probably get it to work but inevitably each screw being a little off would stress the window. This will make sure that the fitment, and more importantly, holes match perfectly between rollbar and rear window if I can pull it off on the second try. I will buy a much higher quality 6/32 tap. I will go slower and back out every few turns to make sure its cutting easily. Once I have match drilled #36 I will tap the holes with canopy off using an aluminum jig to keep my holes straight instead of a $500+ canopy! I haven't drilled the skins yet so that will be a normal match drill.

-Jason
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Last edited by mountainride : 04-16-2019 at 05:29 AM.
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