This was one task I wasn't looking forward to. I have never used a Tap and Die set before. I found that if I used the smaller hand tap holder to start the thread, it threaded into the tube straight. I then switched to the larger holder to complete the job. I used an old toothbrush to clean the chips out of the tap before each use. I asked a buddy for a few tips on technique and he said the take it slow and easy. I actually found that if I didn't stop the tap after each rotation, but kept it turning at a pretty good clip until the thread was fully cut, it turned out better. The plans call for using Lard as a lubricant. It sounds kinda hokey, but it works real well. The lard seems to melt as heat builds when cutting the threads which flows down the inside of the tube. I made sure that I threaded far enough into the tube to allow the use of all of the threads for adjustment if needed. I used a rubber lining in the vice jaws to protect the tube. I found that if I also wrapped the tube in scotch-brite first, it didn't turn in the vise. Be careful if you use sand paper for this, as it can sometimes leave nasty scratches/pits on the tube O.D. The plans show that the throttle rod that extends from the copilots collective to the throttle horn is to be 7" long. I made it per the plans, but it seems too short. I made another rod at 8.25" just in case. Once I get the engine installed I'll choose which one to use.
