Intake broke tap in bolt hole, argh.
#1
Intake broke tap in bolt hole, argh.
My 300 has a warpped exhaust manifold and I cannot bolt up properly. Anyways. I have a another that I was reconditioning to put on. The 2 bolts that bolt the intake and exhaust together were broken off. I drilled them out and was retapping the threads in. Since you cannot get the handle of the tap to turn because they hit the exhaust ports. Well I now have a prblem. I was tapping the threads in so good and it started to show through the inside. The tap snapped off flush with the bolt hole. I tried to back it out with needle nose pliers and it won't bugde. I even heated it and still won't budge. I cannot figure what to use to get the tap out. How would a person drill it out. It would chew the bit up and the hole due to the taps design. I guess I will have to take it to a machine shop. I was hoping to put it on today. ANy of you have this problem and what was the solution?
#3
Sometimes I have had luck with a center punch an hammer. Use small taps and be sure you have your safety glassses on. A trick I use on plastic screws might also work on steel but I have never tried it. On plastic screws I heat a small screw driver blade and insert it into the broken screw. This will make a perfect slot for the screwdriver. Let it cool down before unscrewing. For the broken tap make the slot with a cutoff disk on a dremel tool. Might work. Back in another life, I worked in a tool & die shop and I used a EDM machine to burn the taps out. Electro Discharge Machine.
#4
Join Date: Feb 2002
Location: Saddle Brook United State
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There are tap extractors, that consist of three fingers that go into the slots between the tap cutting edges and turn the tap that way-----Go to MCS----
http://www1.mscdirect.com and search for Tap Extractors there are many sizes up through 1/2" They are not expensive --$15 or so. Try this first before the machine shop. Msc ships fast about 2 days.I have several of the smaller ones and they work fine. You might want to heat the head AROUND the broken tap when you use these extractors or at least soak the area with a penetrating oil to lube the tap. You could also weld a good section of bolt to the broken tap, but you have to be good with a welder.
stractor
http://www1.mscdirect.com and search for Tap Extractors there are many sizes up through 1/2" They are not expensive --$15 or so. Try this first before the machine shop. Msc ships fast about 2 days.I have several of the smaller ones and they work fine. You might want to heat the head AROUND the broken tap when you use these extractors or at least soak the area with a penetrating oil to lube the tap. You could also weld a good section of bolt to the broken tap, but you have to be good with a welder.
stractor
Last edited by stractor; 10-22-2023 at 10:10 PM.
#5
That is what I need. I will have to check with the tool shops around here about one of those. I have broken taps before,but usually there is enough still there that a pair of pliers can thread it out. As for welding is nearly impossible. The tap is just below the lip of the bolt hole. Eventually I will get better tap and dies. These were given to me and I think they are cheaply made. Specially when this one broke when the tap was sticking an 1/8th on an inch through the inside of the manifold. No you can not get at the tap from the inside. You can see it inside the manifold.
Thanks for the advice on tap extractors, stractor. I hope my supplier has one.
Thanks for the advice on tap extractors, stractor. I hope my supplier has one.
#6
Air wand, torch heat, a center punch, hammer, and a water spray bottle. Apply direct heat to the tap, then rapid-cool it with the water, this will make it brittle. Then whack it with the center punch and hammer. It might take a few tries. Use the air wand to blow the chips out. Re-tap it or if it's too far gone, helicoil. If ya got a small enough pry pick, you can pry at it too. Good luck and have patience.
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