[Espeefan]

Wow. It keeps getting better and better. Truly a masterpiece in the making.

I've been working with a lot of 2mm srews on my model and I've come to the point where I'm going to need to tap some 2mm threads into some blind holes as well, in aluminum, so I know what you mean about sweating that job! 2mm screws are pretty small as well. Maybe not as bad a #0-80s though. Looks like you've got a lot more to worry about then I do! About all a guy can do is use some good thread cutting oil, go slow, and keep backing the tap out every turn or so. Maybe even stop, back it out, flush the chips out, or blow them out with air, and continue. At least the bolts and nuts will be easier! Are you going to loc-tite everything as you go?