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Thread Cutting

Thread cutting tools for forming internal and external threads in metal. Taps cut threads inside holes, dies cut threads on rod or bar stock. Sets bundle the common sizes for bench or site work. T-handle and adjustable wrenches drive the tap or die, split dies allow minor diameter adjustment, and thread restorers clean up damaged threads without removing material.

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Taps come in three cuts: taper, second, and plug (sometimes called bottoming). Taper lead-in is longest, easiest to start, stops short of a blind hole bottom. Plug tap has minimal lead, cuts closest to the hole base. If the set lists only one cut per size, it's usually a second tap — middle ground for through-holes and shallow blind work.

Split dies have an adjustment screw. Minor tweak only, not a size-changer — you're correcting for material hardness or cleaning a worn thread, not cutting two diameters with one die. Solid dies hold diameter tighter if you're making new threads to spec.

Match the wrench to the job. T-handles work well on smaller sizes (M3–M12 typical) where you need feel and control. Larger taps need a tap wrench with more leverage and a square drive that won't slip under load. Die stocks hold dies square to the work — critical for starting the thread true.

Material matters. HSS (high-speed steel) covers mild steel, aluminium, and general work. If you're tapping stainless or hardened alloy, look for cobalt or TiN-coated tools — they hold an edge longer under heat. Use cutting fluid. Thick oil for steel, paraffin for aluminium, nothing for cast iron. Back off half a turn every few threads to break the chip and clear the flute, especially in blind holes.

Frequently asked questions

What is included in a tap and die set?
A tap and die set bundles common sizes of taps for cutting internal threads in holes and dies for cutting external threads on rod or bar. Sets typically include the taps, dies, and the wrenches needed to drive them — such as T-handles or adjustable tap wrenches and a die stock to hold the dies square to the work.
What is the difference between a tap wrench and a T-handle tap wrench?
A T-handle tap wrench suits smaller taps, typically M3 to M12, where you need feel and control. Larger taps require a tap wrench with more leverage and a square drive that won't slip under load when cutting coarser or deeper threads.
What does a split die do in thread cutting?
A split die has an adjustment screw that allows a minor tweak to diameter, useful for correcting material hardness variation or cleaning up a worn thread. It does not change the die to a different size — solid dies hold diameter tighter if you are making new threads to specification.
How do you choose between taper, second, and plug taps?
Taper taps have the longest lead-in, easiest to start but stop short of a blind hole bottom. Plug taps have minimal lead and cut closest to the hole base. Second taps are a middle ground for through-holes and shallow blind work; if a set lists only one cut per size, it is usually a second tap.
What are thread cutting tools used for?
Thread cutting tools form internal and external threads in metal. Taps cut threads inside drilled holes, dies cut threads on rod or bar stock, and thread restorers clean up damaged threads without removing material.