When taps get small like that, feeling becomes nonexistant. The smallest tap I use at work is 2-56. The T-handle tap wrench, be it small still swallows up the tap. Then usually comes the dreaded sound of "Snap"
Uggggggggggh!!!!
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I do this all the time at work. Bolt head in the vise, a thread restorer or nut run up against the head and the bolt cutoff with a cut-off wheel to length. Removed from the vise and dressed a bit on a grinder/sander and then the nut removed to smooth the lead thread. However, this is teeny stuff and the OP needs to make several at a time. Seems a good idea if you are using this method. Me? I like bustin scales the old-fashioned way! With a hammer and pins! :rofl2:
I just looked up the tap drill size for an 0-80 # 56 drill (.046") Thats one tiny drill to go with one tiny tap.
This has been a challenging thread to read as my experience in metal work is seriously limited. I feel sort of tapped out now but I'm glad I read it anyway. Its not the first thread I've read through I didn't understand.
This is what you need guys,watchmakers Die/screw plate,are all over the bay for cheap.
Screw the screw in,cut it off with dikes,unscrew,done deal.
http://i22.photobucket.com/albums/b3...ieplate001.jpg