I Had To Make a HUGE 40mm Thread Tap - Its BIG

G'day everyone,
Back in the workshop again and this week I need to make another tap. I need a screw with a large pitch which is also good for transmitting power. That rules out a multi start V thread, which isn't great at efficiently transmitting power. The go to solution would be an ACME or metric trapezoidal tap, which can be single point cut on the lathe. However my lathe wont cut a pitch large enough.
That is fine though because I have the helical milling set up, but that only produces square threads. Not my first choice but we can make do with it.
And that brings us here. I have never made a square tap, and I have never made a tap this big - SQ40 x 8. Machinery's handbook advises that these threads are difficult to cut with a tap, which filled me with confidence.
I will be making a 3 set tap set. 3 is the bare minimum for this thread pitch, but I could have gone up to 5. Each tap will have a different diameter to reduce the cutting force. The first one being 34mm to establish the threads, the second tap being 37mm to widen the cut and the final being 40mm to finish the profile.
I will also need to case harden the taps. i used some hot rolled grade 300 steel which is low carbon. Not my first choice of steel, but we can make it work. I will carburize it int he furnace to increase the carbon content then I will quench it in oil to end up with a tap 55 Rockwell C.
The final tap set looks pretty crazy and out of place. I have never seen a tap this large outside of a pipe tap, although the pipe tap had a much finer pitch. And I will also test the tap in aluminium. I don't have the stones to sharpen it yet so I will keep the test easy and use aluminium. Although the end goal is to tap steel. I hope you enjoy the video.
Mill - Sieg x2.7l
Lathe - Hafco Al250g
#machining #diy #tapbuild
Sqaure thread tap
Massive tap build
Making a thread tap
Square threads
Timestamps
0:00 - Introduction to Sqaure Threads
3:24 - Turning Down The Blanks on the Lathe
9:07 - Cutting The Sqaure Threads On The Lathe
12:00 - Machining The Flutes
14:07 - Case Hardening The Taps
18:52 - Sqaure Thread Tap Set Testing

[@cullenpurkis4593]

Now that you have moved up to tool-making, maybe it's at least time for a power hacksaw...

[@H3xx1st]

When I saw him start that with a hack saw I oof'd, out loud, haha

[@leonclose7823]

Making a set of huge (for the size of your machines), square thread taps, by helical milling, from hot rolled mild steel, then case hardening seems ridiculously ambitious on the face of it. I'm amazed that you have pulled it off. Seriously well done. What is your favourite brand of hacksaw blade?

[@dirkv.9013]

Same here - MacGyver would be proud. For most of the video, I just kept watching because I wanted to see if the next thing would work. You can increase the carbon content of steel by baking it with charcoal? Wow. A+ for raw cleverness

[@Tasarran]

@@dirkv.9013 That's OLD school metalworker stuff there

[@artisanmakes]

I use suttons cobalt blades. Cheers

[@Tinman97301]

So is that a 40mm tap in your pocket... Oh God it is! 👍

[@peterspencer6442]

"Hide yo kids, hide yo wife"

[@alanmartinez45]

A good thing to remember when making the relief cuts. from personal experience using acme taps they always wear out on top of the trailing metal behind the cutting surface, after a few uses it ends up super polished and that seems to make the tap take a lot less torque to move, so for your application it might be worth to polish the taps then sharpen it, you will get a better finish!

[@nevermind1O844]

Should we start a crowd funding campain to buy this man a band saw?!

[@jorgeaura2890]

I'm dying of curiosity now to see what project you will use these massive taps on. Can't wait.

[@leslieaustin151]

Great to see the hacksaw making yet another appearance. Your cuts are a lot straighter than mine. Man! What a project, especially as it’s a project to make a project. Looking forward to seeing that project! Thanks for all your work. Les in UK 🇬🇧

[@artisanmakes]

Years of hacksaw practice has paid off

[@johncoops6897]

@@artisanmakes - It probably builds on the strength you have gained since your teenage years from doing a similar hand/arm motion 😂😂

[@herzogsbuick]

@@johncoops6897 looooooooool

[@kdubbya]

I appreciate that this guy was willing to tell us about all the problems he had. A lot of people leave all that out and make it seem like child's play 🤣

[@Bloodray19]

I absolutely love your videos. Discovered you when I had to be in hospital for 2 weeks in last December, and ended up bingewatching every video you had out at that time

[@hersch_tool]

Outstanding work. Your problem solving approach is intelligent, and skillful, and your execution is fearless. You just dive right in. Respect. Side note, your videos are also fan-friggin-tastic. Making vids is harder than it looks and yours are so clear and easy to follow. I am stealing idea... I mean, "taking notes"... 😅

[@xerxespamplemousse6622]

this is why my brother has several editions of "Machinery's Handbook" going back to the first edition. The information comes and goes, and sometimes the old ways are best.

[@artisanmakes]

Yeah seems that even though there’s is 2000 plus pages they still have to removed old information

[@Skankhuunt42]

For the cutting of the tread, take 2 fix wrenches to get More power and dont get the power from only one side like on the adjustable wrench. For example two 36 wrenches. Great content!!!

[@kyfho47]

What he said. I figured someone would have already beaten me to it.

[@alanmartinez45]

For easier covering with the borax flux wrap a metallic mesh around the flux! Nice work brother!

[@bigmotter001]

WOW, masterfully done. I learn so much from your videos! Thanks for taking us along and take care!

[@killerbanjo]

I don't know what size you did the square drive, but if it is 1 inch or close to a standard socket drive diameter, buy a single socket, cross drill a hole so you can insert a bar and drive the tap using the square in the socket. Pretty sure that would work?

[@slartimus]

But it'd be a lot funnier to make a comically large tap wrench to go with the comically large taps. :D

[@martinswiney2192]

Socket and 3/4” drive impact wrench.

[@a-k-jun-1]

They commercially make 8 pt sockets for use on square nuts. A lot easier to just pick up a socket of the appropriate size if it is a normal size square.

[@martinswiney2192]

Correct myself months later after watching him use the taps. 1” drive impact wrench.

[@andrewlacerenza667]

I love the way you increased the carbon during the hardening in charcoal packing boxes, I'm a hobby machinist and never did that before

[@timturner7609]

Square threads are actually stronger in applications like pressure vessels because they have no taper which would act as a wedge and rip apart either itself or the mating surface when pressiz3d internally

[@PatrickHoodDaniel]

Can't wait to see the application of these threads!

[@charlvanniekerk8009]

Thats honestly pretty nuts. I cant wait to see it in action on whichever project youre using it for. Incredible project, thanks for sharing!

[@robyoung1890]

I have been, and am still, impressed by your strength and persistence cutting large stock with a hacksaw!! I understand your resource and space restraints but that does not dimmish the effort you expend! Well done sir! Great vid too!

[@themasterisback1]

Hey there nice vid! A tip from a machinist and engineer: the relief angel you need to improve the tap more is on the taper of the tap. It's hard to explain in a comment but the cutting tooth have no clearance angle right now, because the outer shape was formed on a lathe. You can easily do this on the grinder by hand on the tapered part of the taps. I highly recommend the video from thisoldtony on this topic. Anyhow keep up the good work and have a nice day 🤘🏻

[@artisanmakes]

I mentioned in the end that I have the intention of doing that but my new set of grinding wheels hasn’t turned up yet

[@DanPetrePhotos]

You made it clear you were waiting for wheels and it will be more difficult to grind into hardened steel. I guess from a project management point of view you get the job done faster by shifting work before the wheels arrive at a small cost of having the grinding a bit more difficult. How long did it take to grind relief?

[@artisanmakes]

It’s usually a fairly quick job but I have yet to get around to it

[@douglasharley2440]

sweet!...can't wait to see what you need those taps for. 🤣🤔

[@Horus9339]

You are truly tapped mate, the size of those bloody things. Well done, you'll be well screwed once you turn them through steel. Thank you for sharing your time.

[@wizrom3046]

PLINK!! ... broke the tap off in the workpiece ...unlikely. 😁👍

[@CheffBryan]

So you say, but literally this last week the boss broke a 35mm. It makes quite the trophy!

[@colinmcmillan2642]

Mind. Blown. Amazing job!

[@merc7105]

Never seen anyone do this. Amazing. Well done mate. Cheers.

[@infrabread]

I keep forgetting just how much chemistry is involved with metalworking. I'm a professional carpenter, so I don't even know what I'm doing here.

[@ronwilken5219]

@infrabread it's just like woodworking just you're working with petrified wood and modified stones. Some basic principles apply to both occupations.

[@artisanmakes]

It’s not too different to wood selection and grain structure that you have to consider.

[@steved8038]

You obviously didn't listen to all the idiots that say you can't make anything worthwhile in a small machine shop, Congratulations for proving them wrong and for all the information and entertainment you provide .Thank you

[@WompWompWoooomp]

Looking forward to that tap wrench video!

[@Hati321]

Can't wait to see the machine you're building.

[@hampopper3150]

One of these days you should setup a electronic lead screw for the lathe.

[@crazynthree]

I can't wait to see the dividing head rebuild 😂😂

[@maciejglinski6564]

tbh the begining with a 1914 machinist handbook with a WHOLE SECTION about why you should NOT do it, immediatelly followed by handsawing commically large pole, immediatelly followed by revelation that you did it 3 times is peak comedy

[@MASI_forging]

How awesome. That is really good 👍👍

[@neilredelinghuys3263]

hi. this is my favourite youtube channel at the moment!

[@chetleonard169]

nice work

[@erniemathews5085]

Good ideas, great execution. Thanks for showing us.

[@scroungasworkshop4663]

Brilliant job.

[@H3rmanHan01]

First time I have seen taps created. This contect was well organized and enjoyable to watch. Many thanks.

[@stevensmart8868]

Nice work. I used to tap some inch and a quarter BSW threads through 30mm mild steel plate, for die sets for sheet metal. Anyhow we used a tap wrench that was about 3 feet long and even then it was hard work. And this is 40mm and square. Good job and good luck.

[@masterQ20]

*Thank you for a very good video. Valuable leason learned!* 👍❤😊

[@patrickbeck4062]

I would just make the drive end 6 sided, so you can use a proper socket and whatever wrench you want. Most times when I and others I've worked with, use larger taps you end up finding the closest socket and using a 3/4 drive rachet anyway, because tap handles that size are too awkward and bulky to be able to use where you need them on a lot of machines (need too much space to spin the handle). Plus if you do it before cutting the threads it will give the chuck flats to hold onto. You could make 6 sides work with a normal tap handle as well if you change the angle in the holding inserts from 90 degrees to 120 degrees.

[@homemadetools]

Good work. We love big tools. We shared this video on our homemade tools forum this week 😎

[@nineoclockhero]

If you weld a bar to the fixed jaw of the adjustables, makes a quick simple tap wrench. Not very fancy, but I'm assuming you're not going to be 40mm tapping for a living. 😄

[@andrewdolinskiatcarpathian]

Holy smoke, I can’t imagine what you need such big taps for. Very interesting video. Thank you. 👏👏👍😀

[@Lone-Wolf87]

Well done. 👍👍👍

[@francobuzzetti9424]

i swear. every time i see a machinist pull up the machinery's handbook i know sh*t just got real

[@imranmahsud84]

Great workout

[@Carrera281]

My respects this is something really outstanding, keep it up!

[@nuneke0]

Or as Crocodile Dundee would have put it: That's not a tap! This is a tap! 🤣

[@repairtech9320]

Great minds think alike. Using an air brush as a mist coolant sprayer. Glad to see it on YT.

[@matiasrodriguez3413]

Para asegurarte que el "Thread Tap" quede centrado podés hacerlo en el torno apoyando suavemente el contrapunto. Esto también permite aplicar fuerza con la llave francesa sin preocupaciones, pues no se torcerá.

[@juliankoenig]

Nice Work!

[@bluefalconcatering]

Great video 😊

[@michaelsimpson9779]

What an effort. Well done you.

[@MyTubeSVp]

22:35 You can have a square holed spanner lasercut out of 10mm steel sheet, or weld up something from 2 pieces of 10x40 flat bar.

[@jamesdrake2378]

I was thinking that guy with your skills cuts the material with a ordinary hacksaw. Respect on that.

[@battleaxefabandmachine]

Very nice work

[@oliverer3]

Finally, a tap that won't break if I look at it funny!

[@HoY_82]

Blacksmiths use an adjustable wrench with a bar welded onto the head for twisting steel, something as simple as that could work as a bigger tap wrench unless you have plans to make one of those too

[@jmyyer]

Impressed !

[@Joe-xq3zu]

I really don't understand why you don't own a bandsaw by now, even a small one would make your life so much easier.

[@Jacklsovakia1]

or a sawzall!

[@Bobo-ox7fj]

or a mitre box 😛

[@christofs-a1834]

Or two f#cks what anyone else thinks. Oh wait!

[@Jacklsovakia1]

@@christofs-a1834 ha nice one

[@BlackheartCharlie]

"Comically large" taps deserve a comically large tap wrench!

[@DudleyToolwright]

The airbrush coolant dispenser is very creative. Thanks for the interesting project.

[@MathMikeAllen]

Hey bud, great content! If you have an adjustable wrench you are willing to sacrifice, a cheap/ excellent alternative to a large tap wrench, is to weld a bar to the adjustable jaw, equal to the length of the handle of the wrench. I carried one with me for field repairs and it did the trick for years. You may be experiencing high side loading on the tap without support on both sides of the centerline of the tap. Hope this helps!

[@Kmnri]

Amazing, I love seeing unusual things being made rather than 9001th vise jaws :D

[@ma-lakshmifabricator7549]

Overall, this is a highly informative and enjoyable video for anyone interested in engineering. It showcases your talent and expertise while providing valuable insights and inspiration to fellow enthusiasts. Keep up the great work, and I look forward to watching more of your content in the future 👍👍👍

[@thealicemonster9217]

So you were saying that you hope that it would follow the groves from the previous tap. Something that I do to prevent cross threading when putting in a bolt is I will start by running the bolt backwards until it falls into the threads, this way I know for a fact that the bolt is properly seated before sending the bolt home. This is super helpful to save your projects and bolts and it doesn't take but a second or two.

[@artisanmakes]

It’s more so that fact that the lead angle of the threads changes with these types of taps. It’s ever so slight but there is a change. I was worried that it might try and cut a different helix as a result

[@thealicemonster9217]

@@artisanmakes Ooh, okay. That makes a lot of sense. Thank you for clearing that for me 😊 That trick of mine is really helpful tho. 😁 I really liked the video, you do good quality work.

[@robgraybeal8089]

Interesting. I liked the video, but I would have purchased a TR40 tap from Aceteel instead of trying to make one though. They cost about $350 US dollars, but that is cheaper than I could make one. I have designed large automated equipment that used large linear drive screws and never had a problem finding large taps or screws. It will be very interesting to find out what this project is. Great video and I truly enjoyed it!

[@betaich]

Prices for stuff like that vary widely depending on where you are in the world. Where I am I would pay as much as you pay for the big one for a way smaller one.

[@bow-tiedengineer4453]

I love the fact that the book was just straight up "Don't do this. You shouldn't do this. It's a pain in the ass. OK, now here's how you do it."

[@arminrichard1836]

i think what you could try when forming the flutes and therefore the cutting edge is grinding them with a dremel and small ball grinder in the lathe with only the crosslide. You should get a pretty prestine finish that way.

[@TheRecreationalMachinist]

Impressive 👍 🇬🇧

[@greaser5691]

That's an impressive project. Greetings from sunny Adelaide.

[@Der_Arathok]

Finally a tap that doesn't break. it rather breaks me!

[@monkeyjustice]

Somebody get this guy a metal bandsaw!

[@babayaga5225]

With the relief should be easier to cut. Nice job!

[@jasonhull5712]

The whole time I was watching you make them taps I was thinking how the heck do you drive or muscle through that large of a tap ! Wheeew, that’s gonna take some grit. Lol 😂 They turned out great looking and left a nice thread though. 👍👍

[@blanix6637]

Holy smokes mate, is that for an oil rig? 🤣 Great work as always. I appreciate your approach "If it works = Success!" Respect.

[@charliesnyder1608]

Great vid as always. please tell me you made these taps for some part for a bandsaw your making to get away from the hack saw?

[@BEDavisBrown]

That's amazing work, I would have thought turning metal cutting taps would be outside the limits of a home machine shop. Did you end up using a cheap airbrush for cooling or did you have to spend more?

[@courier11sec]

I know this is silly, but a bit of me dies whenever I see someone scrape a nonstick pan with a metal tool.

[@ronwilken5219]

As long as his wife doesn't see and he returns them clean to the kitchen cupboard she's none the wiser.

[@Beef4Dinner22]

You mentioned that the helical cutting was using the bottom of the endmill and that was increasing the cutting force. Couldn't you offset the Y axis half the cutter diameter so that the leading edge of the end mill was at the centerline of the part? This would end up with a slightly rounded bottom of the grooves you are cutting, but it would mean the cutting was all done by the sides of the end mill instead of the sides and bottom.

[@alliwantedisapepsi1492]

wow. Just wow.

[@notabagel]

awesome video. for future use, you can buy tapered end mills for machining injection molds.

[@Adam_Swaner]

Let’s get this man a nice bandsaw

[@AnonOmis1000]

Feeling some ToT inspired vibes from your video. I think you got a new subscriber

[@tcurdt]

The hardening process was particularly interesting. Thanks!

[@billdoodson4232]

You really do have far more patience than I have. Brilliant little project, but jeez, my arm hurts just looking at the worn hacksaw blade. Have to say I have a sense of anticipation to see what the main project is.

[@samrodian919]

My arm hurts too and I've got a 4x6" metal bandsaw!

[@HyperactiveNeuron]

I'm REALLY curious what these taps are for.

[@toblexson5020]

They are so impressive taps. Time for a comedically large tap wrench now? (Oh, I said that before you mentioned it. Maybe a ratcheting one?)

[@bscoffeeandwelding7236]

Thats a big ambitious project for a shed guy well done like many others here single sided handle is no good need a double or possibly multi handle tap wrench with lots of leverage especially for steel looking forward to the next one

[@KrAvE4KaRnAgE]

Fantastic job. Would cutting the flutes before the threads help with bit loading/chip removal? Would also prevent the burr on the threads. Not a machinist, just a fan!

[@ego73]

Those are freakin 'UGE!

[@artisanmakes]

YUGE with a Y

[@ego73]

Bloody right! My name's Ian. Yours?@@artisanmakes

[@CatNolara]

Those are some really big taps, good thing if you can make them at home because trapezoidal taps are pretty expensive. Wonder what you're gonna build with those. Anyway, is there a reason you didn't grind in any relief angles this time? Could be the reason why it's so hard to turn. Sharpening definitely should help as well.

[@joedunn7434]

We have some pretty decent sized taps at work but Watching a face mill cut the flats on a freaking tap just doesn’t seem right. 😂😂

[@hillonwheels8838]

Not sure if this would work since I have never done the work you are doing but could you have used a 4mm ball end mill to make the initial cut for the threads then fallow up the final pass with a regular 4mm end mill? You said that the tool puts a lot of end pressure on the bits and it looks like the ball end bits look to be able to handle that load. Love your content and you make it look so easy that I want to get these tools to start making my own stuff instead of having others do it for me.

[@elischultes6587]

When Keith made a odd ball tap I thought he should have found a matching V thread tap to reduce the amount of load.

[@smorris12]

I don't know if the terminology has become blurred or they've died out (my books and tools are all ancient), but "slot mills" are the thing for cutting those threads. They have two flutes and an offset centre divot to allow cutting on both edges. Also, they do tailstocks for use with rotary tables (although perhaps your mill bed isn't long enough) which would have helped.

[@ObservationofLimits]

He should have had his Y axis inwards so the outside edge of his bit was aligned with the center of the rod, rather than center on center.

[@rito147]

What if you cut the lead in taper on the taps longer/ shallower? Would that not reduce initial cutting force when starting?

[@haitchteeceeeightnineeight5571]

Damn, son, you could start the local chapter of the Arcane Yet Functional Leadscrew Generation Society. Very nice.