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Broken taps! HELP!!!!!!!!!

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Kenny Christoph

08-01-2001 18:47:59




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I have a 1941 Case SC manifold that has two of the holes where the exhaust elbow mounting studs go into with taps broken off into them, They are flush with the top of the manifold, so clamping onto them will not work. Does anyone know if these can be removed without too much stress on the manifold? Anyone ever broken a tap like this? Will I need a diamond tip drill bit? I NEED YOUR HELP!!!!! QUICK!!!!

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Gordon (IN)

08-18-2001 07:29:46




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 Re: Broken taps! HELP!!!!!!!!! in reply to Kenny Christopherson, 08-01-2001 18:47:59  
I have had good luck removing broken taps with a "Dremmel" tool and diamond coated tapered dental burrs. Cut through the web of the tap and take it out in pieces. It is a little slow, but can be done without any damage to the part. Good Luck



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Cookie

08-06-2001 08:32:09




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 Re: Broken taps! HELP!!!!!!!!! in reply to Kenny Christopherson, 08-01-2001 18:47:59  
A friend of mine ran a fabricating shop for years before he passed away. He removed broken bolts, studs, and taps by arc welding a smaller bolt, or sometimes just the welding rod to the broken part and using them to garb with vise grips or a wrench to turn it out. I never saw him fail to remove them on the first try!



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Butch (OH)

08-03-2001 06:44:04




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 Re: Broken taps! HELP!!!!!!!!! in reply to Kenny Christopherson, 08-01-2001 18:47:59  
This is more a "next time" post than help with your problem but when you purchase taps try to find carbon steel taps. Most of the hardware store taps are made of HSS. The advantage of carbon taps is when you break one a good whack with a punch and hammer will shatter the tap and you can pick or blow the pieces out of the hole. HSS taps will not shatter when struck. As for your current problem you can try the other suggestions, but stop short of making the problem worse by breaking the manifold or ruining whats left of the threads. Quite a few, but not all machine shops have tap burners. The local one charged me $20 to remove a broken HSS tap. I paid it gladly.

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albe

08-02-2001 07:50:43




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 Re: Broken taps! HELP!!!!!!!!! in reply to Kenny Christopherson, 08-01-2001 18:47:59  
Just heard about this this morning! It probably only works on a through hole that had a broken tap in it. Make the top of the broken tap as flat as possible. Get a punch the same diameter as the top of the punch. Have the piece on a hard surface. Hit the punch a few times with a BIG hammer. This should break the very hard( and brittle) tap. albe



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Dan Lamons

08-02-2001 04:30:31




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 Re: Broken taps! HELP!!!!!!!!! in reply to Kenny Christopherson, 08-01-2001 18:47:59  
Whatever you do. do not put a torch to the broken tap! more times than not Tap extractors fail to remove the tap. My suggestion would be befor you do anything, take to a reputable machine shop and let them remove it and save the headache and expense. If you make several attempts with various methods , hammer and punch, torch. etc. it just makes it more diffucult for the machine shop, which runs up the cost and quality of the repair. good luck.

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ferrell freeman

08-02-2001 04:15:22




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 Re: Broken taps! HELP!!!!!!!!! in reply to Kenny Christopherson, 08-01-2001 18:47:59  
If you, cannot get them out with a tap extractor ,you might try a oxy/ace cutting unit with #0 or#1 tip blowing them out . I,have had to do this several times ,if you say the bolt head is 1/2 then the bolt is more than likely 5/16 which is a small hole but it can done .



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Free Willy

08-02-2001 03:14:04




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 Re: Broken taps! HELP!!!!!!!!! in reply to Kenny Christopherson, 08-01-2001 18:47:59  
I have heard that this method sometimes works:
A. Soak the area with a high quality penetrating oil.
B. Take a stout cotter key, and open it enough to slip down over the flutes of the broken tap.
C. Remove the broken tap by rocking the cotter key back and forth to unscrew the tap.



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Larry Garbarek

08-01-2001 19:39:30




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 Re: Broken taps! HELP!!!!!!!!! in reply to Kenny Christopherson, 08-01-2001 18:47:59  
go to www.mcmaster.com and search for "tap extractor". You will find several that can do the job for you.



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Kenny Christopherson-another question

08-01-2001 23:04:59




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 Re: Re: Broken taps! HELP!!!!!!!!! in reply to Larry Garbarek, 08-01-2001 19:39:30  
Thanks for your help Larry. I am going to order one of these tap extractors. If the bolt has a 1/2" head, does that mean its a 1/2" tap extractor?



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jeff

08-06-2001 14:48:32




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 Re: Re: Re: Broken taps! HELP!!!!!!!!! in reply to Kenny Christopherson-another question, 08-01-2001 23:04:59  
if the head is 1/2 the bolt itself will be 5/16



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Kenny Christopherson-another question

08-01-2001 22:38:13




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 Re: Re: Broken taps! HELP!!!!!!!!! in reply to Larry Garbarek, 08-01-2001 19:39:30  
Thanks for your help Larry. I am going to order one of these tap extractors. If the bolt has a 1/2" head, does that mean its a 1/2" tap extractor?



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Larry Garbarek

08-02-2001 11:59:47




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 Re: Re: Re: Broken taps! HELP!!!!!!!!! in reply to Kenny Christopherson-another question, 08-01-2001 22:38:13  
Don't know which extractor you have settled upon but I'm quite sure that all are sized by the thread diameter, not the head diameter nor shoulder diameter.

You might consider Dan Lamons wise advise to have someone with experience take out the broken tap.



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Mac

08-01-2001 18:56:07




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 Re: Broken taps! HELP!!!!!!!!! in reply to Kenny Christopherson, 08-01-2001 18:47:59  
cant remember where I got them, but I have used Tap removers. These are a finger like object that fits down into the tap flutes. If they are not bottomed out these work great. There are different sizes of these. I would try any local automotive supply. There maybe something better.



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