<VV> Re: BROKEN 4 FLUTE TAP IN CAST IRON

[EUGENE1938@aol.com]

Tim,
I've removed broken taps by making a removal tool out of an 
appropriate sized bolt.  Figure out what size bolt will fit into 
the hole without touching the threads.  Buy a bolt about 4" 
long grade 5 or better with a smooth shank above the 
threaded area.  Cut the bolt just where the threads end so 
now you have a smooth shank only.  Hold the bolt in a bench 
vise with the cut end up and with a hacksaw to form a 90 
degree cross cut about 3/16" deep.  Now take a file about 1/8 
to 3/16' wide and follow the cuts to widen them.  When 
finished the tool should fit down on the broken tap.  Trim as 
necessary to make it fit.  Soak the stuck tap with "PB Blaster" 
for a few minutes and place the tool into place tap it with a 
hammer to set it firmly in place.  While holding down pressure 
attempt to turn the tool back and forth.  If you can get it to 
wiggle you should be able to slowly work it all the way out.  
The same applies to 3 fluted taps, it's just harder to make the 
tool.  I use a hack saw on an angle then finish with a Dermal.

Ed Corson (CORSA member)
IECC - Riverside, CA