Broke tap

Bob Harvey · May 8, 2020

Any info/help would be good. I had to tap(1/4-20) 4 holes for a reason . Turns out the steel is tough. Broke the tap in hole #3 (4 required). How do I get the broken tap out ?

retired farmer · May 8, 2020

If you have a gas welder and a fine tip you can usually burn the tap out enough to pick the rest out. What I do.

TimV · May 8, 2020

Several possibilities--an EDM machine will remove it if you have access to one. Carbide burr will work. Some people have had luck heating and shattering them with a hardened punch, but I haven't had much luck with that method myself--might be just me. There are also tap extractors that typically fit down into the flutes with steel fingers and allow you to back it out, but again, I've had limited success with them--even with high-dollar sets.

SVcummins · May 8, 2020

When it starts back it out and re lube and start again might only get a half a turn but easier than breaking a tap

Steve@Advance · May 8, 2020

The safest and easiest, if the part is small enough to put on a mill, drill it out with a 3/16 carbide end mill.

Sometimes they can be broken out with a punch.

Never a good situation.

Hoenes · May 8, 2020

I read somewhere on here about using a hammer drill on twisted off bolts. Maybe a 3/16 bit, but watch the sides. It worked for me on a bolt, but a tap may be too hard. Worth a try. Maybe buy a new SDS bit, to start with.

M-MAN · May 9, 2020

They make broken tap extractors but they are pricey. If you have a torch heat it up and douse with cold water. Tap it with a punch and it will shatter like glass. Reheat again and let cool slowly.

MeAnthony · May 9, 2020

Chainsaw sharpening bits for your Dremel tool, worked for me on a '97 Dakota 3.9L V6, broken tap in rear exhaust manifold bolt hole. Takes a little time and used 3 or 4 bits but less work than pulling the head. SKU 2421661 on Menards' website.

4wdtom · May 9, 2020

You might want to consider making the pilot hole just a few thousands over the recommended no. 7 size if the material is tough especially if the threaded length is more than the dia. of the fastener. Use lots of cutting fluid, or even just engine oil if you don't have cutting fluid. But lots of it.

dr sportster · May 9, 2020

If it is a four flute tap do a search for Walton Tap Extractor. It removes broken taps.

Jaden · May 9, 2020

Depending on what kind of flutes, I have used a thin needle nose plier to remove a broken tap. Wiggle gently back and forth. Patience!

Bob Harvey · May 9, 2020

Good suggestion, downside it is in a 5" x 5" steel gatepost anchored in concrete !

Janicholson · May 9, 2020

If you have a portable oxy/acetylene torch you can blow it out easiest. heat only the tal, it will start to glow. hit the oxygen and it will be inside the podst resting for ever. Done in about 10 seconds, the post will not get hot enough to change temper. Jim

Broke tap

Bob Harvey

Well-known Member

retired farmer

Well-known Member

TimV

Well-known Member

SVcummins

Well-known Member

Steve@Advance

Well-known Member

Hoenes

Member

M-MAN

Well-known Member

MeAnthony

Member

4wdtom

Well-known Member

dr sportster

Well-known Member

Jaden

Member

Bob Harvey

Well-known Member

Janicholson

Well-known Member

Similar threads