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It happens no matter how careful you are and how straight you drill.. sooner or later one will snap and no doubt it will be below the surface. They sell broken tap extractors but I never had much luck.. solid carbide bits may drill it out if ya dont end up either smokin' em or breaking them too. Heres an old trick I learned way back... only 2 things are needed... a ball bearing and chewing gum. Get a ball bearing to fit the hole.. chew up a stick of gum.. wrap the bearing in the chewed gum and insert into the hole.. get good hammer and wack the bearing good and solid. The bearing will shatter the hard tap or extractor and the gum keeps you from getting a shrapnel wound. WEAR SAFETYGLASSES of course! Remove gum and bearing (bearing will not shatter) Pick pieces of shattered tap or extractor from hole with pick. I have used this trick many times.. worked every time!
I have this problem on a regular basis. I custom build mailing equipment and go through more 8x32, 8x24, 1/4.20 taps. Drilling them is a bear. Great tip. I can't wait to break the next one and give this a try. Thanks.
Yur right Eric.. the carbide tipped masonary bits work real well. They arent as prone to breakage as a solid carbide bit. I regrind used ones and put a lil more angle on them. They cut really well.