Thread metal like a pro: The best tap and die set

Taps and dies were used in metalworking in the early 18th and 19th centuries. The tool was used to create screw threads for nuts and bolts that were to be used with other machinery. 

Joseph Clement was a renowned British engineer and one of the early vendors of taps and dies [1].

The onset of machine milling in the 1860s gradually made the process of threading faster and easier.

Yet, not all can afford an industrial-grade milling machine for just a simple job.

Especially for small business owners and your average project dabbler, a classic manual tap and die set is irreplaceable. 

Today, we’ll be looking at the best tap and die sets around.

Versatility.

Tap and die sets can either be for woodworking or metalworking.

A metalworking set is very comprehensive and can cater to varying-sized materials depending on the number of pieces included in a particular set.

Different types of taps and dies further complement the tool’s range of applications. More on these details in a later section.

Precision.

As stated before, a set must have two components or ‘mating’ parts.

The tap, used for tapping, is good for speed, while the die, used for threading, to thread both a male and female end.

Despite being a manual tool, the tap and die are appreciated by engineers with an eye for detail.

2. Check the durability.

You’d want to look for a set that’s made of high-end steel.

Since you’ll be using it to work with metal, durability will play an important part.

As it is one factor that could spell either an extra expense or additional savings in terms of use and longevity.

3. Consider the size.

A set of 100 pieces that cover both SAE and metric sizes is more versatile than even a similar-numbered set that only covers either of the two.

While you should go for whichever is more versatile, consider which sized set is more suited to your needs, such as the scale and frequency of your projects.

4. Check the included wrenches.

A rethreading kit is not a set without the wrenches.

A normal set would have a tap wrench and a die handle but it’s best to have a T-wrench included in the set. 

5. Think about the size.

You should always consider the price. In the case of tap and die sets, more pieces equates to higher prices, but that’s not a constant.

When considering the price, base it on your needs, as well as the brand name. The more casual the work, the lower the acceptable price range, otherwise, invest in the more premium ones.

A tap and die essentially make screw threads.

The tap is often associated with being the ‘female’ component and is used to make threads for the bolts and thread to fit into.

The process of creating threads in material with a tap is called ‘tapping’. 

A die is associated with being the ‘male’ component.

It is the one used when making screws or creating threads along with a material that functions as a screw/nut/bolt.

Using a die to create threads is called ‘threading.

Just like any other metalwork such as engraving or carving, you can say tapping and threading is a work of precision art. They both require an eye for detail.

1. Determine 1st the number of threads per inch (TPI) using the gauge system that comes included with your set. Once this is good, use the corresponding die to begin threading. 
2. Use a tapered die to determine which side to start.
3. Set your chosen die on the guide wrench and begin to slowly turn to start cutting. It’s advisable to use cutting oil or similar lubricants when cutting metal to reduce friction and heat.
4. Select the appropriate-sized tap to thread the hole for your screws. Use in the same manner as you did the die. Still use cutting oil if possible.

Another related piece of equipment, you might want to look into is a Dremel rotary tool fitted with engraver and deburring bits.

For doing extra bits of detail cutting and fine sanding.

Taps

Taper taps are often used for initial threading because their ends taper to a smaller diameter that’s easier for starting threads.

Plug taps are more the middle-ground between taper taps and finishing taps and are pretty common.

Finishing taps are best for finishing threads as they can cut completely until the bottom of the hole.

Dies

Die nuts are more of a refining tool as they can sharpen existing threads, but cannot make new ones.

Circular dies are the most common and come included in almost every set. Circular dies cut threads on exteriors.

Split circular dies are versatile circular dies that can either be split in half or have just a single split. These are able to take on larger material and can cut subsequently deeper from a shallow, initial pass.

• HSS. Known as high-speed steel, these high-alloy steels are ideal for cutting material as they have high breaking points, cut fast, and can withstand high temperatures. 
• Carbon steel. Carbon steel is a common and highly recyclable type of alloy. It’s durable and highly resistant, making it one of the longer-lived types of materials.
• Alloy steel. Alloy steel is even more durable than carbon steel. Alloy steel can be hardened to a higher degree and is better at withstanding high temperatures and distortions.

• HCS. Known as high carbon steel, a 0.55% carbon content makes these extremely hard and durable. Mainly used for cutting, HSS is known to retain edge-sharpness even when under constant stress.
• Cobalt. Cobalt is used to be alloyed with other metals, improving hardness, strength, and wear resistance. Cobalt is good for adding abrasiveness and greatly improving heat resistance.
• Titanium. Titanium boasts great longevity given its natural resistance to corrosion. It features the highest strength-to-weight ratio of any metal but is relatively less effective at high temperatures.

The overall best must be Greenfield 420361.

Despite the small number of pieces, the combination of HSS taps and carbon steel dies well makes up for it by giving you performance, longevity, and efficiency.

Here’s how:

The HSS taps provide you with good wear resistance when creating internal threads.

While the carbon steel dies to provide you with a more economical choice for threading external material. 

As a plug tap, the Greenfield is so versatile, allowing you to do initial threads and fine-tuned refinements with ease. Despite it being SAE only, we can’t recommend anything better. 

The best value set goes to the Tekton 7560 for its balance of size and cost.

Much like the Greenfield, the Tekton tap and die set covers SAE, but holds a bigger number of pieces at a total of 45. 

With 20 taps and 20 split dies and a 1½ inch die stock adapter, this relatively modest-sized set comes in handy for light to medium applications and can cover most standard thread sizes. 

If you’re looking for affordability and both a metric and SAE set, look no further than the Efficere 60.

This good-sized set is a wise pick for those just starting out or those who are in need of a casual work set.

The Efficere 60 attributes both SAE and metric sizes and can make both coarse and fine threads. 

It includes 20 metric taps and dies and a 20:12 ratio of SAE fractional taps and dies for coarse and fine threading respectively.

Tap wrench

Essentially a compact, T-shaped handle that’s used to turn the tap or other small tools.

The tap wrench shows a very basic design but seems to be the most efficient when it comes to manual turning. 

Of all the wrenches that should be included in a set, this would be the best.

Die wrench

The die wrench works as a handle for turning the die, they are basically what is responsible for creating the threads.

A die wrench can either have a built-in die or have a hole that’s specifically shaped for certain dies. 

Pitch gauge

Also known as a thread gauge, these tools measure the pitch [2] or lead of a screw thread.

A pitch gauge is what you’ll need in order to determine the thread TPI and select the appropriate tap and die size for the job. 

Die stock

Nothing does a better job at creating uniformed threads on various materials than a die stock.

A die stock gives you a guide or framework and enables you to position the die with precision. 

Proper handling of tap and die sets

• Do determine the most appropriate sized set for your needs.
• Do identify which taps and dies are right for the work needed.
• Do make use of the correct accessories to ensure quality control of results.

Improper ways to handle tap & die sets

• Don’t use a set that’s not compatible with whatever size you are working on (E.G SAE for metric).
• Don’t simply use a larger tap or die than what you actually need as this can result in loose fits.
• Don’t simply compromise if you do not have the proper accessories; determine which tool is the best alternative and won’t cause damage to your set and/or project.

The best tap and die set is the Greenfield 420361 with its durable and versatile HSS/carbon steel tap and die combination.

Though it only covers SAE sizes, the small piece count makes it easy to manage and helps you focus on quality job completion.

If you’re after the best value, then the Tekton 7560 is your man. It’s a superb-sized set and the split dies to give you a great amount of flexibility with your threading options.

Looking for both a metric and SAE set in an affordable kit? Then the Efficere 60 should be right up your alley; its highly assorted 60-piece kit lets you do coarse and fine threading and is for both SAE and metric sizes. 

So, ready to tap out? If yes, then do remember these sets as they are among the best the market can offer. We hope you had a fun read with this and we’ll see you in the next one!