> > Blind tapped holes are everyday occurrences commercially, its not a > problem. > Right! While I prefer through holes, there are plenty of places where I can't go through. One thing I make is some cabinet rails that are 8 - 11" long, and have threaded holes in the ends. The part I copied was an extrusion with the tap diameter extruded into the part, but when I make them from aluminum bar stock, I don't have that luxury. I just drill deep and tap it, no biggie. Sometimes I even rigid-tap these, but that can cause binding of the tap, so I more often tap by hand to avoid accidents. That might be a perfect place for forming taps.
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