</font><blockquote><font size="1" face="Verdana, Tahoma, Arial, Helv, Helvetica, Sans">quote:</font><hr /><font size="2" face="Verdana, Tahoma, Arial, Helv, Helvetica, Sans">Originally posted by jx94148:
<strong>While tapping threads in the last of 4 holes, the tap tool broke in the hole. <img border="0" title="" alt="[Mad]" src="images/icons/mad.gif" /> We tried to drill it out but its harder than any bits I currently own. Anyone know what I need to get this out?
</strong></font><hr /></blockquote><font size="2" face="Verdana, Tahoma, Arial, Helv, Helvetica, Sans">A carbide bur in a die grinder or drill...

Just some advice I gave to Ken E (YourMom), since I've done this a couple of times now:

</font>

• <font size="2" face="Verdana, Tahoma, Arial, Helv, Helvetica, Sans">Don't use the gasket to mark the new stud hole locations. They are not exactly the same as the diff housing. Some folks have done this, and then had to enlarge a few of the stud holes in the diff, as they didn't line up perfectly. If you can, do the welding, then grind it flat and cut the notch for the locker fork. Then drop the diff into the axle housing, use a long punch or an indexing tool to accuratly locate the hole locations.</font></li>
• <font size="2" face="Verdana, Tahoma, Arial, Helv, Helvetica, Sans">I didn't use the long studs to fasten the actuator motor to the diff housing, I ended up using long bolts, I'm pretty sure they were 100mm long.
  </font></li>

<font size="2" face="Verdana, Tahoma, Arial, Helv, Helvetica, Sans">Ken, nice job with that switch. Looking forward to hearing about the rest of your project. BTW, I found a truck today, check this out:
http://www.yankeetoys.org/members/klf/Images/Newtaz/
So, the search is over. <img border="0" title="" alt="[Big Grin]" src="images/icons/grin.gif" />

Just another trick for broken taps:
They are very brittle, so put on your safety glasses and use a center punch to break as many "ears" or flutes off as you can. Then try brute force to hammer it thru the hole. Then, make sure you got all the hard peices out of the hole, and rethread with a new tap.

FYI, gun taps have only 2 flutes and don't break as easily as hand taps. A bit harder to find but industrial places carry them. Same price too!

Hope you got it out already!

</font><blockquote><font size="1" face="Verdana, Tahoma, Arial, Helv, Helvetica, Sans">quote:</font><hr /><font size="2" face="Verdana, Tahoma, Arial, Helv, Helvetica, Sans">Originally posted by Erik.B:
<strong> A carbide bur in a die grinder or drill...</strong></font><hr /></blockquote><font size="2" face="Verdana, Tahoma, Arial, Helv, Helvetica, Sans">Thanks Erik. I took care of it with a diamond grinding bit for a dremmel, I think its part 7105 in the dremmel catalog, $10.99 from ACE. Everything comes from Ace cause they are close by.

Everything about this project has been harder than I thought it would be. I do have it all done but the wiring now. <img border="0" title="" alt="[Big Grin]" src="images/icons/grin.gif" /> <img border="0" title="" alt="[Big Grin]" src="images/icons/grin.gif" /> Most of today was spent removing my front axle and installing one with 4.30 gears to match my new rear. That was hard!! I did it totally alone using 2 bottle jacks, a floor jack, and my hand tools. The breaker bar has been very busy the past few days. I broke my 17mm box end wrench and one ratchet, both were Craftsman so now I have 2 nice shiney new ones. <img border="0" title="" alt="[Big Grin]" src="images/icons/grin.gif" /> (again)

The first drive was interesting. I have big time wheel hop as expected so I made the widest turns I possibly could. There were no leaks on either end. <img border="0" title="" alt="[Big Grin]" src="images/icons/grin.gif" /> again. I haven't taken it offroad yet. I won't have time for that for a few days. I have 3 frames of empty film saved for the switches and indicators shots, when I'm finished i'll have around 27 pics of the process start to finish.

I never would have even known about electric lockers if I hadn't found this forum. I'd still be totally stock. Now I find myself adding stuff to my truck on a regular basis including what I consider the 'Mother of All Mods.'

<img border="0" title="" alt="[Big Grin]" src="images/icons/grin.gif" /> <img border="0" title="" alt="[Big Grin]" src="images/icons/grin.gif" /> <img border="0" title="" alt="[Big Grin]" src="images/icons/grin.gif" /> -Matt, (i'll be grining for a while now) <img border="0" title="" alt="[Big Grin]" src="images/icons/grin.gif" />

<small>[ 30 March 2002, 09:46 PM: Message edited by: jx94148 ]</small>

Good job Matt and good luck on the wiring!

It just didn't look right, seeing your truck struggling around the other weekend with no locker. Your truck will be ready for some serious obstacles now!
Scott