Yup, I finally did it - broke a tap in the last hole of a part that represents (at least) five hours of work. If anybody can believe - this is the first tap I have ever broken (I am 63 and been messing with things mechanical since I was 9).6/32 high speed steel tap in merchant steel. As far as I know there is no way out of this one so tomorrow I will bite the bullet and start all over again. Got too confident and failed to back the tap fully out of the hole to clear the chips. No warning; no "oops shouldn't have given it that last bit of torque" thingy; just a sudden'snap'. Didn't ruin my whole day but it came close. And before the suggestions start rolling in - I have no access to EDM tooling, there is nothing sticking out of the hole and I do not have (or have access) to an appropriate carbide drill. Mostly it is a joy to live on an island in the middle of nowhere. Sometimes (and this is one of those times) it can be 'somewhat' inconvenient. One thing I can say; there is no problen with thieves here. I have dubbed the three miles of ocean between my outfit and the nearest center of civilization as the 'fool filter'.
Speaking of a ruined day - Please check out the URL in my sig line and (if at all possible) join the team. So far there are only five members of this NG on board. I am sure we can do better than this.