How to Drill a Broken Tap

Save

A broken endmill can truly put a halt to work and can be very difficult to remove. As the tapping of holes is often something that is done at the end of the manufacturing process, it is often essential to remove the broken tap to save a part that has many hours of work already done on it.This removal process can often take quite a bit of time. By slowly cutting away the broken tap, you can remove it and start all over again and save the part from being wasted.

Things You'll Need

  • Carbide Endmill
  • Manual Mill
  • Tap Removal Pick
  • Remove any of the broken tap area that sits above the surface with a carbide endmill. Get as close to the surface as possible. Use an endmill that is smaller in diameter than the tap that has broken. The reason for this is that you will want to also use the carbide endmill to flatten the surface inside the hole you were attempting to tap.

  • Use the same carbide endmill to drill the bulk of the tap away so that you can use a pick to remove the remaining chips embedded in the tapped hole sides. Slowly lower the endmill down on the flat broken tap surface. Use the drill stop on the mill you are using and only lower the endmill after all of the tap has been removed at the depth you have set. At first, the endmill will jerk around due to the fact that the surface will have imperfections; this is the critical time to be the most careful as the jerking motion can break the endmill easily.

  • Drill slowly to the bottom blowing debris out of the hole as you go. Keep the carbide endmill cool by using a coolant mister or spraying coolant on the endmill manually. These chips can get caught in the endmill and cause breakage. Carbide endmills can cut hard metals, but are very brittle and are prone to breakage due to trauma.

  • Use a tap removal pick to get any of the material that was not removed by the carbide endmill. Since a tap has many flutes, there will be small chunks of the broken tap in the walls of the area that has been tapped. They must be thoroughly removed before you attempt to re-tap the hole. These pieces will cause a new tap to break and you will have to start all over again.

Tips & Warnings

  • Go very slowly and use the handle of the manual mill to feel the when you can move deeper. While it is cutting the hard material of the tap, the endmill will jerk around quite a bit. Use the drill depth stop to assure that you do not go too deep, too quickly, as this action will cause your endmill to break.

References

Promoted By Zergnet

Comments

You May Also Like

  • How to Remove a Broken Drill Bit

    While doing standard maintenance around the home or while working on an elaborate project, you can accidentally break off a drill bit....

  • How to Tap a Hole for a Thread

    Tapping threads in metal will allow you to secure a bolt to the metal without the need for a nut to hold...

  • Drill & Tap Instructions

    To attach removable components such as brackets, handles and bearing housings to metal or plastic, the correct size hole must be drilled...

  • How to Remove a Broken Easy Out

    Easy Outs are used to extract broken-off metal bolts that have lodged themselves in a hole. Easy Outs are made from hardened...

  • How to Calculate a Tap Drill

    A tap is a cylindrical metal tube with thread on one end that is used to create female threads in a pre-drilled...

  • How to Drill and Tap a Broken Bolt

    When a bolt snaps while you're working, it’s more than a source of frustration: It’s also a delay in finishing the job...

  • How to Drill Out a Broken Exhaust Stud

    The bolts and studs used to assemble a vehicle's exhaust system and connect it to the manifold are exposed to extreme temperatures...

  • How to Remove Broken Taps

    Taps are threaded tools used to create threading in a piece that requires the insertion of screws or bolts. It also can...

  • How to Drill and Retap

    When you're installing a bolt into a threaded part, sometimes the bolt will break. Should that happen, you will be stuck with...

Related Searches

Check It Out

3 Day-to-Night Outfits for the Work Week

M
Is DIY in your DNA? Become part of our maker community.
Submit Your Work!