DIY: Drilling & Taping Threads Into Aluminum

Difficulty Level

Tools/Supplies Needed:

• drill bit set
• tap set
• lubricating/cutting oil
• drill press
• hammer
• center punch
• clamps
• safety glasses

Procedure:

• ensure that the object you are working with is clean
• ensure that the tap you are using is clean
• mark out where you would like the threaded hole, then using a center punch and a hammer mark the center of the hole
• the center punch marks the center of the hole and will reduce the risk of the drill bit wandering
• using a drill and tap index, determine what size drill bit is required for the hole
• the drill bit must be smaller than the tap size
• clamp the object down to ensure it doesn't move while also reducing the risk of a safety hazard
• use cutting oil if needed when drilling the hole
• clean the hole before getting ready to tap threads
• apply cutting oil to the tap and hole
• ensure the newly drilled hole and tap is lined up correctly
• don't use the drill press' power for this procedure
• slowly feed the tap down to the object and turn the drill chuck by hand
• apply cutting oil when needed
• feed the tap all the way in the hole, then loosen the chuck and allow the chuck to be removed from the tap
• remove the tap by hand
• clean any cut material away from the hole
• clean tap when done before putting away

Frequently Asked Questions (FAQ):

How much pressure should I apply?

Apply medium pressure. Too little pressure and the tap won't start, too much and the threads will be damaged or you do risk breaking the tap.

Video tutorial on how to drill and tap threads into aluminum. In this video I have used a specific type of tap called a "gun tap" which allows me to make a straight run/cut of threads into the material without having the need to continuously back the tap out of the hole to keep the cutting threads clean. Other types of taps need to be backed out of the hole after a few new thread cut in order to reduce the risk of material binding and keeping a clean cut. It is always good practice to buy high quality taps as they will last a very long time and it reduces the risk of breaking due to higher quality materials used. The piece I am working with today is an anti shudder valve from a Volkswagen diesel. The reason I am added threaded holes to the unit is so that I am able to install grub screws to hold the boost pipe in place without it popping open under pressure and causing a boost leak. The tabs on the pipe are worn out therefore the grub screws will hold it in place instead. This is an inexpensive and easy fix for the current issue. A new replacement pipe from the dealer is worth $100, eventually down the road it will run into the same problem.