Adding a pocket clip to a Gerber folding sportsman

[donnord]

I have Gerber FS2 that I am going to put a pocket clip on. I have gathered the clip, the 1-72 screws, 1-72 tap and #53 drill. My questions are the the brass where I will be drilling is about 0.150" thick, I would rather not drill through the bolster but to a depth of about .125. I can do that on the drill press pretty easily, but the tap is a taper tap and full threads don't really start until about .125 up the tap. So I was thinking I would tap as far as I can go and then grind down the end of the tap a bit to make it a bottom tap and then run the treads again. That should work??? The screws are too long as well so I figured the dremel should take care of those. Suggestions? something I am missing?

 

[killgar]

What I'm thinking about is how fine the threads are on a 1-72 tap. If you grind the tip down you could very easily create a burr that could prevent you from re-threading the tap into the holes, especially in a soft metal like brass.

Shortening screws is easier because you can thread one or two nuts on them before grinding them down and when you remove the nut it helps to clean up the threads at the end. But the screws are a lot softer than the tap, so this method might not work as well on the tap.

 

[donnord]

I had that thought as well. My intent was to add the clip to the pivot end "Tip Down" but if I use the other end Tip Up then I have more material to work with. Regarding the Tap I will try it as is, if need be I may chuck it up in the drill press and use a carbide stone to grind it down a 1/16" or so. I guess I could order a bottom tap as a friend suggested, but that would be too easy right.

 

[donnord]

Well it went OK, those tiny taps are tricky to work with. I tried to tap the first hole with the drill press chuck rotating it by hand, those threads came out a little loose. Starting it on the drill press, one thread or so and finishing by hand did the trick. I did apply a drop of epoxy to each screw just to make sure they stay put. If I do this again I would prefer to use 2-54 screws. Shortening the screws was easy, I used an electrical crimping tool that has a screw cut off for #4 screws but it worked great on the #1s. Thanks for your advise.

 

[killgar]

I'm glad it worked out. .

 

[Phydeaux]

They make bottom taps that cut threads almost to the bottom of the hole. I usually start the hole with a regular tap then switch once the threads get started.

I used 1-72 screws to attach a pocket clip to the smallest of the Al Mar Ultralights. The 1-72s hold extremely well, I've accidentally bent the clip without damaging the screws or threads. Threads are tapped into the Mycarta handle.

I made a thin plate with 1-72, 2-56,4-40 and 6-28 threaded holes. I put my screw in it and tighten it so it doesn't rotate. Cut and file to length, back it out (which straightens the threads) and I'm good to go.