I have never made an actual die. Im not sure what metal I would have to use. Where do I get it? I do have the tap. Im not sure of the process from start to finish. Would I have to harden the die after tapping It? I can order one but I would have to order a dozen to amke them cost effective and then hope 11 other people would want to buy one.
I assuming your going to use it to cut acrylic or PR or something like that so it wouldn't have to be made out of high speed steel or something to that effect, I have used O1 (Oil Hardening) tool steel many time to make my own cutting tools.
The trick would be to get the holes which create the cutting edges in the right locations.
What I have done in the past is find another Die that is close to the size I need and copy it as far as hole locations, and you want to make it the adjustable type.
First turn the OD to the correct Diameter and cut to the correct thickness.
Set up and drill and tap your threaded hole with your tap, remember to use a c-sink to create a lead in angle.
Now set the die up on your mill and somehow locate the holes for your cutting edges (using your sample die). (I usally clamp the two together in my vise with a V-Block)
Drill or drill and bore the holes for the cutting edges. I usally drill then finish to size with my boring head and a small boring bar it gives a better finish on the cutting edges.
Then if you want you can put the hole and threads in for the adjustment screw, it you have a die holder that has the pointed set screw and the other screws to hold the die it wont be necessary. (you can use the pointed set screw to set the adjustment).
Now heat the O1 tool steel until it gets Red, but not so red that it starts burning the metal off the surface. drop it in the oil (watch out for flash back)
Pull it out once it cools, and wash it off, and heat it up until it starts to turn blue, and let it cool.
now take an abrasive wheel and cut a slot through the die to allow it to be adjustable. (look at your sample)
Now if you want you can get a dremal or die grinder and a small round stone and touch up your cutting edges, to sharpen them.
Try it on a peice of scrap, and see if it cuts the right size if it's too big squeeze the die down a small amount, if its too small open it up a little, this adjustment can be controlled by your die holder if its set up right.
Ive made several taps and dies this way when I was into minture modeling there's not a lot of demand for taps and dies for super small screws.
I'm thinking of making a PDF showing how to make a tap (Maybe even triple start) for those that have the metal working tools at home. (if you can make the tap you have the tool to make the die) :biggrin:
Good Luck. Its all a learning experiance :wink:
