Removing Broken Taps

Post by **MochetVelo** » Tue Feb 27, 2018 7:04 pm

Taps tend to break off, especially smaller ones. This is a frustration, but it happens to the best mechanics. Here are several ways to remove them.

1) CENTER PUNCH METHOD

This simple idea actually unscrews the tap a tiny bit at a time. You get a center punch and hold it at one edge at the steepest angle possible to the broken tap. Give it a sharp rap. Then position the punch on the opposite side of the broken tap and wack it. This method works well, but takes some time. Here's a link to a good thread on the subject: http://forums.aaca.org/topic/305879-broken-tap-removal/

2) EDM

"Electrical Discharge Machining" burns a rather precise hole into the broken tap. These machines can be purchased for as little as $1500 (see eBay). Many machine shops have them. Check this video of one working:

3) GRINDING

Products such as Omega Drill can be used to drill out broken taps. These bits a pricey, however.

4) WELDING

Another old trick is to add weld to the top of the broken tap and slowly work it back and forth with a ViseGrips or the like.

Phil