Tap Handle (Threading)

I didn't have a handle for my larger taps, so I built one using a two piece design, here is the original sketch written on a discarded bench grinder housing because I was too lazy to get paper.

A better sketch with dimensions:

The goal was to make a tap handle which will hold my entire range of larger taps, here is a 1"-20 tap on the left compared with a 5/8".  In order to do this I had to mill the square halves small enough to fit the smallest but also leave enough space for the biggest taps.

First step, since I'm using 5/8" round stock, I milled the top flat.

Using the dial indicator stand to help get an accurate depth dimension.

Then milling the relief slot for the next cutter.

Milling the square half with a 45° cutter.

Drilling a hole with #7 drill for a #10-32 bolt to go through.

Drilling and tapping the other hole #10-32.

Afterwards, the reverse side of the non threaded hole was counter bored.

Then the other half was made.  I drilled and tapped the ends 1/2"-13 for optional extension handles.

Here is how the square part of the tap sits.

I made the extension handles out of 1" aluminum, drilled and tapped the end to 1/2"-13 as well and put a set screw.  This was done so I can just insert a piece of threaded rod, circumventing the need to cut external threads.

Milling flats on the pieces of 1/2"-13 threaded rod so the set screw will secure it to the handle.

The tap handle fully assembled with the extension handles.

With the 1" tap.

With a smaller tap and without the extension handles.  I made them removable for ease of storage, or in case lack of clearance or if I don't need as much leverage.

Everyone loves close-ups of knurls.

The extra leverage made easy work of tapping in the lathe.

Now I have a tap handle for every occasion.  The one in the middle is just a piece of aluminum with a square hole filed in it and securing bolt, only good for one size (3/8").  The T handle one on the right is for smaller taps.

I used a similar two piece design when I built my die stock a while back.