This is the tap I am using: 
http://www.mscdirect.com/product/details/58607482?rItem=58607482
The drill I am using is 10.5mm which is 0.875 of 12mm so I would say that seems 
fairly large.  The OSG online tool recommends a 27/64” (10.7mm) drill, so I am 
very close (0.008” difference).  Also, if I was using OSG's tap they recommend 
23.8764 IPM which equates to a spindle speed of 400 RPM.  I can try that (I 
used 300 RPM), but I suspect I am going to have the same (torque) issue I had 
before.  And perhaps the answer is I just don’t have enough torque at low 
spindle speeds to do it in one pass…

-Tom

> On Jan 22, 2016, at 12:00 PM, John Thornton <j...@gnipsel.com> wrote:
> 
> What kind of tap did you use? I use only ElectroLube coated taps from 
> OSG. OSG has an online tool to select the correct tap and drill for each 
> job. I once had to deep hole tap in some 7075 and my normal taps broke 
> off. I used the tool and got the right tap and drill so the hole size 
> was correct for the job. Tapping charts usually use 75% thread depth 
> which is usually OK for a depth = diameter, for deeper depths you need a 
> bigger hole.
> 
> JT


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