Removing broken tap

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Well, I did it again and broke off a 1/4-20 tap in an aluminum piece. There was a piece of one of the flutes still above the surface but that quickly broke off with the pliers. My forum search turned up mixed reviews on disolving it with alum, drilling it out with a carbide bit or EDMing it out. Carbide bits were very expensive and I would have to wait for it to be delivered and it was Sunday so no EDM shops were open. I decided to try welding a nut to it because it had worked with broken bolts before. The first try did not get good attachment and broke immediately. On the second try I ran a countersink down the nut to bellmouth it and it welded much better. I was able to start wiggling it back and forth before it broke. The third try I shot some tapping fluid down the hole and was able to get it out - no damage to the threads at all. JimCut an MGB and widened 11" C4 Corvette suspension and LT1 Chevrolet power & 6 spd. Pictures here:Part 1http://forum.britishv8.org/read.php?13,7581Part 2http://forum.britishv8.org/read.php?13,22422
Reply:That has worked for me as well buuuut then there sre those times that the whole piece gets buggared. But then what are the options? I'm glad it worked for you.
Reply:I've seen broken tap extractors advertised, but I've never tried one.  (Hope I never have to, either).  They have fingers that slide down the flutes to turn out the broken piece.America Needs AMERICA'S Oil!!!"Global warming is the greatest scam in history ...There is no run away climate change. The impact of humans on climate is not catastrophic. Our planet is not in peril."--John Coleman, Founder of The Weather Channel
Reply:Nice save and tip.  BTW, if you didn't know already, sticking the tap in bees wax makes tapping aluminum (and SS) a lot easier.MM200 w/Spoolmatic 1Syncrowave 180SDBobcat 225G Plus - LP/NGMUTT Suitcase WirefeederWC-1S/Spoolmatic 1HF-251D-1PakMaster 100XL '68 Red Face Code #6633 projectStar Jet 21-110Save Second Base!
Reply:Originally Posted by duaneb55Nice save and tip.  BTW, if you didn't know already, sticking the tap in bees wax makes tapping aluminum (and SS) a lot easier.
Reply:Originally Posted by steve45I've seen broken tap extractors advertised, but I've never tried one.  (Hope I never have to, either).  They have fingers that slide down the flutes to turn out the broken piece.
Reply:I have used them as well, they work well when the tap simply snaps and its not too hairy.If you managed to get it real screwed up and there are chunks of the tap stuck in the hole, then they don't work so greatYup
Reply:Over the years I have made many repairs for people.When they bring me a piece with a broken off tap and i try all the methods mentioned or they did then there one last one that always works....And before i tell you i will tell you that a lot of times the tap broke in the hole because it was NOT a bottoming tap and should have been.I take a hardened steel punch and hit the broken tap and it shatters into pieces.Then i dig out the pieces ,clean and re tap. It is a little messy but when it is finished the customer is always very grateful.They would not come to you - UNLESS they had already tried and let all their friends try, THEN they bring it to you..Like one time I was working in a HONDA dealership as a mechanic and was asked to do a tune up. The bike just would not come into alignment for timing and i discovered that the camshaft had been installed upside down. The customer looked really surprised when they came to pick it up and the tag said it was tuned up. I had an additional charge for fixing the improperly installed cam. So many times they don't even tell you the whole story..AWS certified welding inspectorAWS certified welder
Reply:Sorry double post.AWS certified welding inspectorAWS certified welder
Reply:I've got a 2x56 tap broken off down in a very small piece of machined steel. There are no tricks for one like that. It is where it is. Piece still functions fine as is. One of these  days I may get a replacement/backup for this part and then I may mess with it for giggles.
Reply:Funny thing, though ....  I've been reading this thread all along, I myself have found, the older you get, the less taps you break.   Can't remember the last one  .....   But I do remember, the PITA and the time wasted, working with broken taps.   Patience, patience ........ and following correct proceedure .....
Reply:If it's a through hole I use the shatter method too, it works good.DewayneDixieland WeldingMM350PLincoln 100Some torchesOther misc. tools
Reply:I have had good luck with tig welding using a socket head cap screw.I also have used the shattering method with good results. EDM I only use as a last resort due to the machining times involved. Sorry for the Dime as I did not have a 6" rule handy. Attached Images
Reply:Originally Posted by mark8310Funny thing, though ....  I've been reading this thread all along, I myself have found, the older you get, the less taps you break
Reply:im 22, i have yet to break a tap...