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I was installing the thermocouple for my pyro this evening and now half of the tap is stuck in the exhaust manifold. I was using cutting oil and clearing the threads after every 1/2 turn. It is a Snap-on tap, 1/8-27 NPT. The tip of the tap is pretty much flush with the manifold and I can't get a bit to drill through the hardened steel. Any ideas on what I can do?
You will have a hard time drilling or even punching a tap. They are already hardened and they never break except with the convex side facing you so you cannot drill in the center.
If it is flush with the manifold, I would use a dremel cutoff wheel and try to cut an x in the thing, then punch and drill with a super hard bit right in the center. Then extract after applying some serious heat with a torch.
I recently went through a similar thing trying to remove my nerf bars when I snapped a bolt head. The thing was so rusted, I ended up drilling the bolt out.