Hayes HD dump truck...RCP's style

[RCP57]

For the small stuff I always drill the holes a little larger than the recommended size and tap by hand...carefully. For tapping 3mm holes, I use my cordless drill but don't tighten the chuck up super tight. Again using caution! I also use silicone spay or alcohol for lubricant.

I broke off my favorite 3mm tap recently in a customers box. The tap was getting dull and I was trying to thread a hole near a weld. The alum gets soft and galls easy where its been welded and I was trying to tap it dry(lube messes up powder coat). Anyway it broke off, I said a few bad words, calmed down and tried to grab the end that was sticking out. I got it to move but it broke off flush causing me to say more bad words. I tried heating the area with the TIG torch thinking it would swell the aluminum and make the hole loose. That didn't work but I noticed that the tap was melting so it gave me an idea. I TIG welded a nail to the broken tap and wound it right out! What a relief!