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03-16-2012, 09:06 PM
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Join Date: Feb 2010
Location: GTA, Ontario
Posts: 826
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What to do?
I have the heated Dynon pitot tube and the SafeAir mast. I drilled and then tapped the holes to 6-32, joining the mast to the pitot tube. The first 3 holes went fine, then on the 4th hole, the tap broke....argh!
What's the best method to deal with removing that? I started to drill it out, then stopped...I think I'll make a bigger mess. Take it to a machine shop or does someone have abetter method?
Thanks
Don
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03-16-2012, 09:27 PM
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Join Date: Aug 2011
Location: Hillsboro, OR
Posts: 154
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Broken Tap Remover
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Roy
N174RT (RV-7A) first flight 5/31/11, 1780hrs as of August 2020:
Tip-up, Lycon IO-360 EXP, WW 74HRT, AFS 5600T, AF-Pilot, IFD440, SL-30, echoUAT, D100 for backup, CQ1 headsets, CMW E-Lift
Our other riveted aluminum monocoque RV is a 25' Airstream
Past aluminum monocoque vehicles:
N601RT (CH601HDS) First flight 5/03, 1550hrs after flying 8 years: 912ULS, GNS430W, SL-30, D10A Sold
1995 Midnight Pearl NSX w/BBSC Sold
EAA Chapter 105 board member 2010->2015
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03-16-2012, 10:28 PM
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tap
If there's a machine shop nearby I'd just take it to someone that deals with problems like this often. Why buy a tool and wait for it when you can just have it taken care of. If it's boogered up they can install a helicoil for you.
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03-16-2012, 11:14 PM
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Join Date: Mar 2005
Posts: 5,685
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There is some value in learning to deal with these problems yourself
Buying the tool and learning remove the broken tap has some value.
Bob Axsom
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03-17-2012, 02:19 AM
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Join Date: Nov 2009
Location: Adelaide Australia
Posts: 218
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Trying to remove a broken tap is bound to cause much pain. take the part to a shop that has an EDM machine and they can remove it painlessly.
Most modern tool shops have EDM machines. 
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Phil
LAME (Aust)
RV7 99% finished
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03-17-2012, 07:46 AM
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Join Date: Feb 2010
Location: Gardnerville Nv.
Posts: 2,828
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TIG or MIG weld a nut onto it, starting the weld into the bottom inside of the nut, add bees wax and remove while hot, done this many times at work over the years.
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7A Slider, EFII Angle 360, CS, SJ.
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03-17-2012, 08:24 AM
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Join Date: Jun 2005
Posts: 3,275
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Do you have a picture?
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03-22-2012, 06:20 PM
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Join Date: Feb 2010
Location: GTA, Ontario
Posts: 826
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Update
Thanks for the suggestions folks. I didn't take a picture before I took it to a tap expert. He looked at it and said "wow, that's going to be a tough one". Not what I wanted to hear. I told him that there couldn't be any heat applied to the area and also the cost of the unit.
Once he found out the tap was in aluminum, he suggested the easiest way to get the tap out was to apply liquid alum. The liquid alum will react quickly with the tap and basically rust it out. As the aluminum is non-ferrous, it should be a non event.
It's going to take a few days for the liquid alum to do it's magic, but he did say that a few drops should do the trick.
Once I get it back, I'll post the pics.
Keeping my fingers crossed.
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