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broke head bolt

Are you saying that the bolt is broken, and the tap is broken, and the tap is loose in the bolt, but won't come out?
 
we can't drill it the metal is to hard but there
are 4 edges on it, if i can't get an idia we have to pull the head off and torch it out, don't wan't to do that.
 
A machine shop with an EDM would be the easiest but I would probly buy a hand full of hard small round grind stones for a dermal and plan on spending a fair amount of down time as I ground the center out. In all of my years I have only broke two taps that size in a hole removing the threads of a broken bolt. First one I tried to break the tap out with a punch and had to end up putting in a plug insert. The second I ground out with a Dremal. Not sure which took the most time.
 
Any chance you can grind the tips of a pair of needle nose pliers to fit into the flutes of the tap.
 

A year or so ago, someone told on here about putting some sort of pins down in the flutes and some how gripping them to turn it out. Maybe he will come along.
 
I have in the past used a piece of tig wire bent in half and stuck down in the flutes and managed to twist it out. Really hit or miss most of the time only other way is like you said a torch.
 
What about dropping 2 small nails into the tap groovs and using a screwdriver between them? Probably bend the nails, but maybe not.
 
2 allen wrenches down wrenches down the the flutes clamped together with a vicegrip ant turn it out like a t handle
 
Hit it with a hammer and punch to break it loose then back it out as the others have suggested.

Failing this heat the tap (only) with a torch, cool it with wax (as candles are made of) and try backing the broken tap out.
 
You can split the tap from flute to flute with a plasma cutter and take the pieces out with needle nose pliers. Works great.
 
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