Contact Irwin. Even if you plan on getting another set, they should replace this, and they need to see these pictures. They need to know that they (or more likely their suppliers) are selling a defective and potentially dangerous product.
I sent it to Irwin and they replaced it. New one came in a box Made in China on the side. That is when I replaced it with a starrett.
That thing looks great! Yup, never seen them state side, but now of course it’s something else I need…I'd go with a German one for this. The Starrett is really nice but the price is ridiculous. The Exact 04965 is 29€ and seems to be made from sintered powder (didn't know they make something like that with such processes, I know they make carbide tools this way). There's also a 28€ version from malleable iron, and a 13€ zinc casting which is probably similar to your broken Irwin.
But personally I most commonly use these:
It's called the Kugelwindeisen (ball tap wrench?). I do not know if they are known in the US. There are 5 standard sizes, every one has 4 different holes to cover all the standard taps. For what I need I usually only use the size 1 and size 2 - and together with the size three that's probably 99% of my needs, those are ~ 15€ each if you buy the steel versions. They are compact and non-adjustable. Since it isn't very complex to make them from steel, and due to their geometry, I believe they are much stronger. The ones I own must be over 50 years old. They don't slacken like a cheap adjustable does...
Same Orion brand also sells a forged steel adjustable tap wrench for 22€. I'm quite confident this tool will perform for a long time just as well as the Starrett...
-Not to knock the OP but those photos are a textbook example of what happens when you stress something made from zinc die-cast, also sometimes called "pot metal". Zinc die-cast works just fine for carburetor or transmission bodies but is absolute sh*t for any sort of structural integrity on a tool like this.
-Yes it is porous, that's part of the telltale sign of a cast metal. Zinc alloys are brought to a molten state, then pushed under high pressure into the mold. Zinc die-casting is unparalleled in high production for producing a near net-shape that holds detail and thin sections while being relatively low cost to manufacture. The smooth surfaces that appear to be polished are a result of the mold surfaces being polished, the molten zinc alloy mimics those mold surfaces. While ideal for high production components, zinc alloys are a poor material for most anything subjected to stress. Manufacturers of cheap tools will use zinc alloys because it's cheaper than steel and estimate that most buyers of cheap tools won't know until after the purchase.that's some porous looking metal, looks like a sponge. How they got the finish to be so smooth and polished when the inside looks like that is quite an accomplishment.
That Gearwrench set is exactly the kind of thing I've been looking for, just ordered one.
junk pot metal?
-Read my earlier post above. Yes it's a zinc die-cast alloy also sometimes called pot metal. Learn to recognize this **** and avoid it for tools/tooling.
I can usually tell by the weight if I handle it, always seems full of some sort of gas.
So I’ve been obsessed with these ball style tap holders since you posted them. I’m going to be in Germany in a couple weeks and would love to find a set while im there. Are these the kind of thing I could find at a hardware store or would I want to order them and have them delivered somewhere?I'd go with a German one for this. The Starrett is really nice but the price is ridiculous. The Exact 04965 is 29€ and seems to be made from sintered powder (didn't know they make something like that with such processes, I know they make carbide tools this way). There's also a 28€ version from malleable iron, and a 13€ zinc casting which is probably similar to your broken Irwin.
But personally I most commonly use these:
It's called the Kugelwindeisen (ball tap wrench?). I do not know if they are known in the US. There are 5 standard sizes, every one has 4 different holes to cover all the standard taps. For what I need I usually only use the size 1 and size 2 - and together with the size three that's probably 99% of my needs, those are ~ 15€ each if you buy the steel versions. They are compact and non-adjustable. Since it isn't very complex to make them from steel, and due to their geometry, I believe they are much stronger. The ones I own must be over 50 years old. They don't slacken like a cheap adjustable does...
Same Orion brand also sells a forged steel adjustable tap wrench for 22€. I'm quite confident this tool will perform for a long time just as well as the Starrett...
There is a problem with this system any buyer should be aware of: the ratchet is switchable forward or backward, but not locked setting. So when tapping, you continuously switch the directional lever while going forward and reverse to grind up chips. Most ratcheting tap holders (Starrett etc) have a neutral locked setting and is fine. This is a severe design error on this model. it is a shame, since otherwise the system is well put together and functional.We have the Gearwrench ones that come as a pass through ratchet handle and a tap holder. They work well if you aren't abusive and I really like the ratcheting aspect.
Homemade, verylittle play.
Sounds like it would work fine with spiral point or spiral flute taps though so maybe not a design flaw but certainly a design limitation
Pretty restrictive for a manual tap handle if so. The taps gearwrench sells with it are regular also. So in that context, it seems a significant blunder with an otherwise nice tool. The issue makes it frustrating to use in spite of being well made.
My enco one does that. My starrett does not. The only difference really is the starrett has the jaws as part of the body where the enco has a pair of jaws held together but pushed apart with a spring and the threaded sleeve you tighten it with holds it all contained. Of my smaller "regular" tap handles, my starrett is the only one that doesn't loosen also. The bigger ones that are two halves where the handles both screw inward to grip the tap don't loosen either, but are of a different style.
Excellent setup (IMO).
www.harborfreight.com
