Well plan c and d came together today. I was able to tap easily using10/24. Initially I thought 8/32 but didn't want to risk anymore chances.
So moving on I, drilled two more holes for gib holders, and using the countersink knowledge, tried 6/32 again. Well that went bad
, then realized my holes are on the wrong side of workpiece. So now need to redo my mating dovetails again
. So after removing broken tap I finished in 10/24. Still need to find the tap holder. I remember hearing the telltale clanking of it going all the way down an behind the tool box after throwing it
I had never planned on hardening, I was hoping for reduced long term wear using a tool steel vs softer steel. Would of liked the ways to be hardened but this is personal preference and as you say would be worth nill as far as machining is involved, but is nice to brag to the Buddys
I think most issues were not countersinking coupled with being round , so thanks to who pointed that out. I will follow advise on small taps since all of mine are 3 flute. Thanks for all replys