SonexBuilders.net

Hi,
I'm looking for advice/tricks on tapping the end for the axle for the 10-32 bolt that holds the wheel pants. I have experience with hand tapping aluminum and some light steel but this little project seems destine to break off the tap in the axle.

Plan:
-pre-drill hole with #21 bit
-plenty of cutting oil
-reverse tap when resistance increases to clean treads

Does anyone have experience with the 10-32 tap Aircraft spruces offers? Part #: 12-08102 $2.85/per

Jim

Jim,
I believe the Sonex axles are a big AN bolt. That is only 120 KSI. Should not be too bad.

I don't know about everyone else, but I wish I had cut something like 1/4" off the length of my axle bolt before I drilled and tapped it. The axle assembly is wider than the inside of the wheel pants, so the pants have a pronounced bulge where the end of the axle presses against the outer half of the wheel pant. Very annoying for putting the pants on, and just looks wrong.

As for tapping, do just as you suggested, and stop shortly after each new resistance. Back out a half turn, then go at it again. It will take a while, but that's OK. Taps are hard but brittle, so go slow.

Well, that was far more easy than I was expecting! I did drill and tap a bit deeper per mike's suggestion that I may cut down the axle length later.

Jim

Make sure it is good quality HSS tap, not plain high carbon steel. Have had low cost HSS steel taps that were junk. Get good name brand made in USA. Pricey, but they will save a lot of grief and last longer.

Also use a specialty tapping fluid not plain oil. Have have had best luck with a product called Tap magic pro-tap cutting fluid. Unless you are running a machine shop, 16 oz. can will last a lifetime. Only need a few drops per hole and it makes a huge difference compared to plain oil. Am sure others will chime in with their favorite cutting fluid, but this one I know works.

As to cutting off ends of axle. Not if you will be using the 5.00 x 5 tire. Had to add spacer to mine after spreading wheel pant to fit over that and GP brakes, assume will be similar if using Sonex hydraulic brakes.

David A.

Hi all,
I totally agree with david, buy a good quality tap, and tap fluid. I had a tap break off slighly proud from the end of axle. Tried eveything to get it out. No luck. Went online and did some research. Took it to a speciality machine shop, the owner took pity on me ( luckily a pilot that owns a C210. ) removed via EDM electro discharge machining. Think like a laser. $20. Incredible. Removed and threads that we cut were untouched. Also bought a better quality tap from him. All ended up well.
WaiexN143NM
Michael

DCASonex wrote:As to cutting off ends of axle. Not if you will be using the 5.00 x 5 tire. Had to add spacer to mine after spreading wheel pant to fit over that and GP brakes, assume will be similar if using Sonex hydraulic brakes.

I have the standard Sonex wheels and tires, and the Sonex hydraulic brakes. And I need a good 1/4" cut off the ends of my axles. Drilling the hole deep enough to have the option later, is a good idea. Then you don't cut the axle until you know you really need to, but the hole is deep enough either way.