Broken Tap in a 2 Way tool holder

Old Iron said:
OK I've been building a 2 way tool holder for a project I'm working on. I got it all finished but needed to tap 4 wholes 10/24 and broke the tap on the last whole.

I really hate to start over and make another one so I need some ideas to get it out. It is broken even with the top and bottom.

I tried using a punch to move it but that didn't work either.

Paul
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I usually do the punch and use plenty of compressed air in the hole and repeat several times the air will shrink the tap a little! my 2 cents. Ebert
 
If it's a carbide tap, soak it in a soppy paste of baking soda all night. If possible, put it in the oven at very low temperature to keep the primordial soup warm. Carbide will crumble like egg shells after 8 hours of soaking.

It also works on HSS but not as well.


Ray
 
If you have a butt end of a carbide end mill, grind a sharp cornered 4 side pyramid at 60 and running the mill wide open (and that won't be too fast, use light pressure and cut down the middle. Use an end mill just large enough to clear the flute's root. The remaining "teeth" will fall out. Use air to blow away the chips, which will be very, very hot. That's how it works. Extremely negative cutting angle, very strong edge generates enough heat to soften the HSS and cut it away. Just kind of peck your way through. If you want, you can use a round scribe type punch to flake out the teeth as you go if you want.
Hardest part is getting a more or less flat break on the tap to start with. This worked on larger taps as well. Can't tell you how many 1/4-20 taps I've broken in Inconel and titanium, and other exotics and drilled right out like that. I keep a few carbide "tap cutters" on hand, although I haven't needed one lately. Just remember, carbide is not very flexible, so if you see it try to deflect, move the part around to minimize that. Also, it helps to use the quill at near it's full extension and don't let the lock drag. You want a bit of slop there too.
 
I found a cute batch of toys on eBay . Busted Tap removers they are a 4 rod


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Sorry.. They are a 4 rod unit that pushes down in the holes of the tap and then you screw them backwards they work if the tap is not too siezed


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Walton makes those. Also a three flute version. But you're right, if the tap is tight, those won't work. The little fingers are pretty flimsy. I've never had much success with them.
 
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