Broken tap..help?

[xblueh2o]

Agreed on the tap extractor.
Money spent on good tools is never wasted.

[BillL]

Those carbide armor drills look nice.

This is crude, but if you can not get to the back to remove it or heat to loosen, then just back it up, hammer it through and either use a plate nut or #8 screw.

If you want to spend several days getting materials, then get some nitric acid, make a pool around it with clay and dissolve it. It should take about 30 min. That is after all the trouble to procure the acid. Only nitric.

Edit: Link for Tap-X http://www.westtool.com/default.aspx...cts_tap-x.html

[mdoyle]

Walton Tap Extractor, Google it. I have used these with great success. it will cost $20.00 to 25.00 dollars.

[Mike S]

I have had success in the past with beeswax, and heat.

Apply a dab of beeswax, heat with a heat gun, let cool. Repeat a couple times, and then use a tap extractor or other device to twist the tap out while the heat gun is still in use.

Dont rush things, just get the broken tap moving a little, then remove the extractor, and clean out any chips------then reinsert the extractor and repeat as needed. Keep it well lubricated.

Kahuna's idea of using snap ring pliers is a good one, probably cheaper than an tap extractor, and easier to find.

Just in case you are not familiar with tap extractors, see here. http://aviationmiscmanuals.tpub.com/...4-23-9_100.htm

Good luck, just remember that sometimes it just simply will not come out--------dont waste too much time/effort/sanity on this, move the hole over a bit and redo.

[kjlpdx]

I know many will strongly disagree , but after 15 yrs of flying and maintenance, I'd use only #8 screws everywhere. #6's are pretty, but very easy to bugger, plus it's just something else to keep track of.

[rmartingt]

I haven't gotten to that part yet... why is a tapped hole called out? A nutplate would be much easier and less susceptible to complications...

[Mike S]

Originally Posted by rmartingt

.. why is a tapped hole called out?
.

Typical Vans engineering ---------costs less, weighs less, quicker and easier than a nutplate, and (when done successfully) works just fine to do the job it is intended to do.

[petersb]

Originally Posted by Simon Hitchen

Well, surprises still happen this far into the build. I managed to snap a 6-32 tap this morning while tapping a hole in the longeron for the rear inspection plate.

A quick attempt to drill into the tap failed and wandered, so that was quickly abandoned.

Any thoughts on the best way to remove this would be greatly appreciated. Once out I can enlarge to 8-32 if needed.

Many thanks

Happened to me too, probably everyone that has built an RV.

My solution was to simply tap it through using a drift punch, then installing a nut plate. Very simple, quick and easy

Peter

[rocketbob]

Avoid store bought taps like the plague. USA-made titanium nitride coated two flute taps are the way to go. I routinely do hard tapping on the milling machine and lathe, rarely if ever stopping on aluminum. Stanless, inconel, etc. different story. Tapmagic for aluminum or in a pinch kerosene is good for tapping.

[Simon Hitchen]

Thanks for all the guidance guys.

I'll follow the advice and see how things work out.

Many thanks