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10-29-2015, 08:38 AM
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Join Date: Dec 2006
Location: New Orleans, LA
Posts: 474
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Broken Tap
I was trying to tap the roll bar on the very bottom hole by the skin. Apparently I missed it when I tapped all the other ones and the darn thing broke off in there. Since I have the skin, then the back window before I get to the roll bar, I can't get any kind of a tool on it to grab it, so it will need to be drilled out or something. It is hard to keep a drill bit on the center of it and it wants to wander. Any suggestions on the best way to get it out? Thanks.
__________________
Stoney
First RV-14 Flight 04/17/2016
Serial #140087, N214SW - Sold
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10-29-2015, 08:52 AM
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Join Date: Dec 2007
Location: Flagstaff, AZ
Posts: 2,653
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I am not sure why you can't get a tool in there if you could get the tap in there. When this has happened to me, I used a modeler's needle-nose pliers. They are short and have very fine ends that will fit where the flutes of the broken tap are. Jam them in and then use the pliers as a handle to back the tap out. Drilling a tap isn't likely to be successful, so your other possibility is to punch the tap through, redrill the hole, and tap to a larger size. Personally, that would be a last resort for me.
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Patrick Kelley - Flagstaff, AZ
RV-6A N156PK - Flying too much to paint
RV-10 14MX(reserved) - Fuselage on gear
http://www.mykitlog.com/flion/
EAA Technical Counselor #5357
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10-29-2015, 09:14 AM
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Join Date: Dec 2006
Location: New Orleans, LA
Posts: 474
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Quote:
Originally Posted by flion
I am not sure why you can't get a tool in there if you could get the tap in there. When this has happened to me, I used a modeler's needle-nose pliers. They are short and have very fine ends that will fit where the flutes of the broken tap are. Jam them in and then use the pliers as a handle to back the tap out. Drilling a tap isn't likely to be successful, so your other possibility is to punch the tap through, redrill the hole, and tap to a larger size. Personally, that would be a last resort for me.
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Yes, there is no getting any kind of pliers on it. You have the dimpled skin, then the plexiglass, then the broken tap and it broke part of the way in the hole. There is nothing sticking out and it's a #6 hole, so I'm guessing the last resort is my only option.
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Stoney
First RV-14 Flight 04/17/2016
Serial #140087, N214SW - Sold
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10-29-2015, 09:30 AM
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Join Date: Oct 2007
Location: Mission Viejo, CA
Posts: 212
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Broken tap
The first thing to try is a "Tap Extractor"
http://www.amazon.com/Walton-10104-F...=tap+extractor
You'll need to order the correct size and number of flutes.
If the extractor does not work, you'll need to drill it out. This is not an easy task because taps are extremely hard, too hard to be drilled out with any standard drill bit. Solid carbide (not cobolt) is your best bet.
http://www.amazon.com/Kodiak-Cutting...bide+drill+bit
Good luck!
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10-29-2015, 10:38 AM
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Join Date: Jul 2005
Location: Hubbard Oregon
Posts: 9,035
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Taps can not be drilled... they are hard tool steel just like a drill bit.
I recommend trying the tap extractor.
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Opinions, information and comments are my own unless stated otherwise. They do not necessarily represent the direction/opinions of my employer.
Scott McDaniels
Van's Aircraft Engineering Prototype Shop Manager
Hubbard, Oregon
RV-6A (aka "Junkyard Special ")
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10-29-2015, 10:43 AM
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Join Date: Dec 2006
Location: New Orleans, LA
Posts: 474
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Quote:
Originally Posted by rvbuilder2002
Taps can not be drilled... they are hard tool steel just like a drill bit.
I recommend trying the tap extractor.
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Thanks Jake and Scott. It's on it's way! Amazon loves me, or my money that is. Hopefully that will work.
__________________
Stoney
First RV-14 Flight 04/17/2016
Serial #140087, N214SW - Sold
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10-29-2015, 11:22 AM
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Senior Curmudgeon
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Join Date: Sep 2005
Location: Dayton Airpark, NV A34
Posts: 15,420
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The tap extractor should do the job, if you are careful in using it.
Try using a pin punch and hammer to GENTLY hit the broken tap a bit, just to loosen it up a bit------you broke it because it got frozen in the hole, and you want to get it unfrozen before you start using the tap remover.
When you are twisting the broken part out, use a bit of lube on the threads, and use a back-and-forth twisting motion just like when you are running the tap in.
DO NOT FORCE things---------the extractor is not as strong as the tap itself was, and due to the additional thickness of the plexi, your extractor fingers are not going to be supported as well as they could be.
Good luck, take it slow, and you should be just fine.
__________________
Mike Starkey
VAF 909
Rv-10, N210LM.
Flying as of 12/4/2010
Phase 1 done, 2/4/2011 
Sold after 240+ wonderful hours of flight.
"Flying the airplane is more important than radioing your plight to a person on the ground incapable of understanding or doing anything about it."
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10-29-2015, 11:28 AM
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Join Date: Jan 2005
Location: Irvine, CA
Posts: 873
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is there a particular type of tap that is stronger than others, so you can avoid the problem of broken taps? Are there certain types of taps that should be avoided?
__________________
Mark
RV-12iS Fuselage
RV-9A Project: Sold
VAF donation made for 2020
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10-29-2015, 11:29 AM
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Join Date: Aug 2011
Location: Jeffersonville, IN
Posts: 393
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Quote:
Originally Posted by rvbuilder2002
Taps can not be drilled... they are hard tool steel just like a drill bit.
I recommend trying the tap extractor.
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In a garage environment I partially agree.
In a machine shop environment with the right tools, equipment it is very possible. In fact I recently drilled out the center of a drill bit, and then proceeded to tap it in an effort to pull it out. (had 10" of 3/8" drill bit buried in steel).
Drill and tap worked great, but I also had no issue spending ~$700 on tools to do it. OSG drill was used, and I still have a spare on my desk here at work.
This was with some high dollar equipment though, a garage shop does not have.
Your best bet is extractor, if that fails sometimes you can use a punch and shatter the tap.
__________________
Jeff Scott
RV9A First Flight 9/30/19
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10-29-2015, 11:38 AM
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Senior Curmudgeon
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Join Date: Sep 2005
Location: Dayton Airpark, NV A34
Posts: 15,420
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Quote:
Originally Posted by rv9builder
is there a particular type of tap that is stronger than others, so you can avoid the problem of broken taps? Are there certain types of taps that should be avoided?
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As a rule, longer lead taper helps, but that is not the biggest issue.
Stay away from bottom taps unless you NEED to use one.
The issue is usually operator error, not bad tap.
Good lubrication of the correct type for the material being tapped, frequent reversal to break the chips, frequent removal and cleaning out of the accumulated chips----------these are the keys to using a tap. And, developing a "feel" for the drag as you cut threads.
If you are using a Harbor Fright tap, adjust your technique to accommodate the lesser quality.
__________________
Mike Starkey
VAF 909
Rv-10, N210LM.
Flying as of 12/4/2010
Phase 1 done, 2/4/2011 
Sold after 240+ wonderful hours of flight.
"Flying the airplane is more important than radioing your plight to a person on the ground incapable of understanding or doing anything about it."
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