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Tool Talk Discussion Forum

Dang! Snapped the tap...

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Regor

08-20-2005 08:23:51




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Well, with Mr. Murphy's help, I was just about finished tapping a 8-32 hole and the tap broke- about 3/8" worth inside a 1/2" steel rod. Turning slowly, in and out, I thought I had it under control. Hmmmm.
The rod is epoxied into a handle of a tool I'm making and the threaded hole is intended for a retainer screw. I would really prefer to use this hole location if at all possible. So, how does one extract a tap and save the threads??
Thanks, guys for any input.
RogeR

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RegoR

08-22-2005 07:06:28




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 Re: Dang! Snapped the tap... THANKS! in reply to Regor, 08-20-2005 08:23:51  
Thank you all for the excellent suggestions and advice.
Over the weekend, I tried many of those suggestions, but finally had to abandon the broken tap to set a new hole- this time all went well.
You guys are great!
Roger



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dr.sportster

08-21-2005 12:09:38




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 Re: Dang! Snapped the tap... in reply to Regor, 08-20-2005 08:23:51  
Walton tap extractor from MSC.When it works it works great when it dosent work it bends the extractor tool.Its a great feeling when it actually works.It does not if the tap is jammed in good.Once I drilled tiny holes all around a tap in an aluminum casting and pulled it out then went oversize.Same casting welded aluminum and closed the hole and started over.This was days not hours later.



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Glen in TX

08-21-2005 09:27:50




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 Re: Dang! Snapped the tap... in reply to Regor, 08-20-2005 08:23:51  
I got some of those tap extractors but if you buy some you will need extra needles or wires for them because those break too. Music wire or spring wire is some very handy stuff to have on hand and will will to help turn those out too. Good luck.



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big jt

08-20-2005 23:42:17




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 Re: Dang! Snapped the tap... in reply to Regor, 08-20-2005 08:23:51  
Yeah I know the feeling. Your heart sinks and you say things like Oh shucks darn wish that hadn't happened (or something like that LOL)

Did this myself about a year and a half ago putting a DRO on my mill. Third hole in the bed, About the same size as what your are talking.

Ordered a Tap Extractor from MSC. These tools have fingers that slide into the flutes of the broken tap and will back the broken part out. Follow the directions and clean the chips out. Use patience and by wiggleing the tap back and forth gently it will soon work loose and back out. You will need to know the number of flutes of the broken tap when ordering the extractor.

The sets show up on ebay occasionally and are good buys there also but check with MSC before bidding.

Might want to get some Tap Magic tapping paste while you are ordering from MSC. If you do much shop work have them send you a catalog. Lots of stuff (something like 5000 or 6000 pages) in there that you can't get at the hardware store and reasonable prices also.

Have included a link for the 3 flute extractor. They have ones for 2 and 4 flute taps if you look.

HTH

jt

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Hermit

08-20-2005 21:07:45




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 Re: Dang! Snapped the tap... in reply to Regor, 08-20-2005 08:23:51  
I've used a small pair of c-ring pliers to go into the hole and twist the broken tap out. Sometimes the straight pliers work better, sometimes the 90 degree ones work better.



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Easy

08-20-2005 20:30:56




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 a six pack to a guy with a edm machine .... in reply to Regor, 08-20-2005 08:23:51  
I would call around to area shops. This might PO some people, but we had guys come around to my dads shop and we did little jobs like that for $0, because it was really hard to put a price on it. A 6 pack of beer is cool. A naked woman with a cold six pack is better. A naked woman witha cold 6 pack and carrying a hot pizza.... BEST!!!! mybe I am getting a little carried away...lol.



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Davis In SC

08-21-2005 15:56:04




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 Re: a six pack to a guy with a edm machine .... in reply to Easy, 08-20-2005 20:30:56  
I try to help out the guy off the street that needs a tap burned out, etc..... Unless he insists that I stop , & do it right then..... Bad thing about doing a job while customer is there, he wants to stand right in the way....



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DL

08-20-2005 19:53:54




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 Re: Dang! Snapped the tap... in reply to Regor, 08-20-2005 08:23:51  
Hey Regor,
I'd have to agree with a few of these posts... I think you're screwed! The problem is... you've wedged a small tap in a deep hole. (If you stop & think about it, the odds are AGAINST you getting the tap out... it is obviously bound up tight in the hole... that's what caused it to break in the first place!) I've only successfully removed broken taps with two methods... use a drift & hammer to shatter the tap in the hole, then work out the pieces (difficult with an 8-32) or with EDM (expensive). I assume that since you're making this part, you don't want to spend a lot of $$... Is it possible to just "blow out" the hole & drill/tap to larger size???
Good Luck! DL

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MAC,IL

08-20-2005 19:17:55




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 Re: Dang! Snapped the tap... in reply to Regor, 08-20-2005 08:23:51  
Anyway you look at it, it"s gonna be a PITA. If you want to try and remove it, try 2 small allen wrenchs on either side of the broken off pc. Say a nice prayer and just maybe you can back it out.



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Slowpoke

08-20-2005 16:35:09




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 Re: Dang! Snapped the tap... in reply to Regor, 08-20-2005 08:23:51  
Not having anything to loose, I would start by cutting two wires about an inch long from a steel cable, like a 3/8" diameter aircraft cable..... That steel should be strong and tough. Slip each piece down opposite sides of the tap, set vice grips or pliers verticly as close as possible to the tap, grab wires and try to back it out. Sort of a poor man's tap extractor. Of course you could also use music wire of the right gauge if you had some. I find that using tapping fluid or at least WD40 makes it a lot easier to turn a tap.

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abe rossman

08-20-2005 12:04:55




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 Re: Dang! Snapped the tap... in reply to Regor, 08-20-2005 08:23:51  
Well since you have broken off suck a small tap good luck.

I have been a tool and die maker for 20 years and have broken more taps than i care to think about.

The best way is you can get you piece into a mill or lathe and use a carbide endmill to pick at it. Sometime you can take a punch and bust the tap up into little pieces, but it uwually damages the threads.
Or maybe you can take the piece to a machine shop and they can run it through there EDM machine to burn the tap out.

Or maybe since you are at home you can use a dremel with a very small carbide burr to eat it out of there.
They do make things called tap extractors but they are not very good unless you break a larger size tap.

How this might help you out.

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Logan

08-20-2005 19:26:17




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 Re: Dang! Snapped the tap... in reply to abe rossman, 08-20-2005 12:04:55  
I broke one off in a head for a MH 44 one time....man are they a pain in the a$$ to get out. simple task as to replace the manifold required to take the head completely off and took 2 months to complete the task. We ended up cutting it out with a torch (man did that take a while too) and then had to retap it ever so carefully....lol.
good luck



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