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Tool Talk Discussion Forum

removing a busted tap

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bgiese

12-26-2004 04:16:33




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need some idea"s I broke a 1/4 20 tap off in a cast flange on my tractor, it is in a blind hole I"ve tried to cut a slot in it with a burr grinder to use a screw driver to turn it out but the burr grinder did not even cut into it, tried turning it out by tapping on the corners of the tap but as easy as it broke all it does is bend or mashes the ends of punches thanks for any advice




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Jon Bohlander

12-26-2004 16:55:57




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 Re: removing a busted tap in reply to bgiese, 12-26-2004 04:16:33  
Tap extractors work sometimes but the best way by far is MIG welding a nut to the tap. On smaller taps or taps deep in a hole a carbide endmill will cut it. Probably want to tqke it to a machine shop for that.



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jhill

12-26-2004 16:42:05




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 Re: removing a busted tap in reply to bgiese, 12-26-2004 04:16:33  
Take it to a machine shop that has an EDM (electro discharge machining) machune and have it burned out. It will come out perfect. I have also used an acetelyne torch if its in cast iron. Heat the tap up good and hit the oxtgen. It will burn out clean



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LUCASS

12-26-2004 15:16:34




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 Re: removing a busted tap in reply to bgiese, 12-26-2004 04:16:33  

I USUALLY TRY A TAP EXTRACTOR,IF ITS TO TIGHT I BURN IT OUT WITH OX/ACY TORCH. IF ITS A PEICE YOU CAN LAY WITH THE HOLE FACING DOWN THE SLAG WILL FALL OUT, LUCAS



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ScottP

12-26-2004 08:44:05




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 Re: removing a busted tap in reply to bgiese, 12-26-2004 04:16:33  
Use Skinners method except use a small brazing tip. When the tap gets near molten turn off the gas. The heat from the tap and the oxy. will burn the tap. May take several times depending on how deep the tap is. Wont ruin the tip and no chance of hitting the lever.
Scott



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paul fergie

12-26-2004 07:57:19




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 Re: removing a busted tap in reply to bgiese, 12-26-2004 04:16:33  
About the best way I have found to romove one is with a small high speed grinder and a small rotary file..Just file away at the center then use an easy out ...Works every single time..Hope this helps



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Bill WI

12-26-2004 07:45:03




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 Re: removing a busted tap in reply to bgiese, 12-26-2004 04:16:33  
Might try a carbide drill or 1/4 masonry bit and put in an insert if all else fails. Depends what the tap is made of, if it's high speed steel it's probably not going to soften much as air hardened steel has a high draw back and the tap removers in theory look good, but you have to blow all the chips out first and hope none are wedged in. An edm type tap blaster works great, but it's limited to work you can put in a tank, so thinking Skinners trick is worth a try. Broken taps or easy outs are nightmares. Bill

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Skinner

12-26-2004 07:12:02




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 Re: removing a busted tap in reply to bgiese, 12-26-2004 04:16:33  
A sure fire method to get it out, if all else fails. However, I have to warn you that I"ve been told it"s not good to do, but I"ve done it for over 20 years.

I take a small cutting tip for my torch, heat the tap until it"s cherry red, then turn up the oxygen (do not press the lever). Turn the o2 knob up slightly, the tap will turn white and the torch will sound like a machine gun. With each pop, a section of tap will be removed. This will remove the tap, and will not hurt the cast if you do it right. When your done, take a small pick and remove any slag that is stuck, it will peel right out.


Warning
The poping in the torch is back burning. I do have spark arrestors and checks on my torch.

Tip will be ruined.

Wear goggles!

Machine shop may be safer. Actually, it is were I learned to do this.

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Joe M (GA)

12-26-2004 06:15:05




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 Re: removing a busted tap in reply to bgiese, 12-26-2004 04:16:33  
The Tool Trucks (snap-on, MATCO, etc)have a tool to remove them. It looks like a four bladed key that fits in the grooves and allows you to screw it out



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Van in AR

12-26-2004 04:34:12




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 Re: removing a busted tap in reply to bgiese, 12-26-2004 04:16:33  
Heat the broken tap with a torch to cherry red, this takes the temper or hardness out of it. I then use dental burrs to cut it out. A high speed quality drill bit will also sometimes work at that point. Good luck.
Van



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dr.sportster

12-26-2004 08:19:43




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 Re: removing a busted tap in reply to Van in AR, 12-26-2004 04:34:12  
There is a tool set called Walton Tap Extractors avaailable at machine shop supply houses.It will only work on a four fluted tap.It wont work if the tap is really jammed in .I bought this for around 50 bucks ten yrs ago.First time I used it it worked great second time the tap was too stuck[same aluminum casting]Wont work on spiral taps.If this fails I dremel with sears carbide bits into hole and vacuum chips as i go.The method with the oxy/acet sounds good for iron.Remain calm take your time.Think like a metal surgeon.It feels great when you get it out.

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Gerald J.

12-26-2004 09:48:04




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 Re: removing a busted tap from aluminum in reply to dr.sportster, 12-26-2004 08:19:43  
A very good way to remove a tap from aluminum is to drop nitric acid on it. That acid will eat the steel, but not the aluminum.

Aluminum is very bad about curling and locking the tap. Its most important when tapping aluminum to back up the tap a turn about every half turn forward to break off the chip, or the chip will lock the tap every time. Then you break the tap trying to work it loose.

Gerald J.

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Bus Driver

12-27-2004 05:43:14




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 Re: removing a busted tap from aluminum in reply to Gerald J., 12-26-2004 09:48:04  
I have not tried it using nitric acid on aluminum, but until it is demonstrated otherwise, I would expect the acid to rapidly destroy the aluminum. If the "aluminum" happened to be magnesium, the chemical reaction would be quite vigorous.



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