OK. There was a hole in the passenger side head that had some damaged threads. So I went and bought a tap and die set. So I started to cut new thread and it didn't seem like it was working right so I stopped, before my threads were shot. Well my dad says I did this before. So he picks up the tap and starts cutting threads. It seemed it was going good when...SNAP. http://www.chevelles.com/forum/mad.gif The tap broke off inside the head. There is about 1.25 inches of tap inside the hole. Since it was cutting in, its pretty stuck. Has anybody that has ever had this happen? How did you get it out? If I can't get it out, the only choice I have is to re-take apart my motor and swap heads form one side to the other. If its important the hole that the tap broke off in, is the hole where the alternator goes. Thanks.

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1970 Chevelle SS396
402 BB, 400 turbo, 12 bolt, 4:10 gears.
TC# 1430
2002 Silverado HD, 3/4 ton. 6.0, 4 speed auto, 4.10 rear and 4 wheel peel.

FYI next time you do some tapping, use some lubericant and you turn forward an 1/8th turn or so then backward then forward, backward, this keeps it from getting too tight then every once and a while turn it all the way back out to get the metal out and start again, this way you don't break taps (learned this at an early age by trial and error but at my old companies expense, they had TONS of cool equiptment lathes, taps, saws etc. made for alum, machining and they just said figure it out http://www.chevelles.com/forum/smile.gif i had so much fun busting stuff) anyway, try some needle-nose pliers because the tap should have 2 sides that you can fit it into and slowly try turning it back and forth and break it loose. or try a small punch on the lip and turn it enough to break it loose.

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1970 SS396 AKA 454/4spd
My Chev-Hell Page (http://hometown.aol.com/jnkb2cool/home.html)
GOLD Member #783
Ft.Worth, Tx
(OO=ss=OO)

Yeah i hate when that happens, especially when its your new tungsten steel set http://www.chevelles.com/forum/mad.gif. And snapping the 1/4-20 unc tap is alright, cuz you never have to use that one, its rare http://www.chevelles.com/forum/mad.gif. Luckily it snapped in an unassembled engine unlike yours, and i wasn't to worried about finding a replacement.

Yeah, well I would suggest drilling a small hole in the tap, then using an easy out. Then go to sears and buy a quality replacement. Thats what i ended up doing. Good Luck.

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1970 Chevelle Malibu 2d

Chev hell is right. I have used needle nosed plyers to get out a broken tap. The other thing is there are two types of taps. One has a point, and the other is flat.(Don't know if this is the correct term but I always called it a bottoming tap) When the pointed ones bottom out they break! The flat ones are made for a hole like the alt hole. they hit bottom and stop.

There are tools specifically for this task. They are called tap extractors. A good tool supplier will have them. Take the broken one with you so you can get the correct size extractor.

I went to all my local parts and tool dealers in my little town and no luck on the tap extractor. Does anybody know of a company that carries them. I tried the needle nose and no luck, tried the punch and no luck. This thing is stuck. I found some tap extractors on the interent, but they are for large companies that buy in volume. Does MAC-Tools carry them? Or snap-On?

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1970 Chevelle SS396
402 BB, 400 turbo, 12 bolt, 4:10 gears.
TC# 1430
2002 Silverado HD, 3/4 ton. 6.0, 4 speed auto, 4.10 rear and 4 wheel peel.

Bad. Can you get something like 2 very small screwdrivers down between the groves in the tap? If so, you may be able to put another screwdriver at 90 degrees between the two small ones and twist it out. Kind of like a barrel wrench. Man, I sympathize with you on this one. This sucks!

Had this happen on a head bolt. I had to chip it out piece by piece and then use a thread repair kit to repair the threads.

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Randy Johnson
70 Chevelle

I don't know if you have access to a welder or not, but my mechanic doesn't sweat this stuff. He broke a bolt in one of the heads on my engine, I asked him what he was going to do, he welded a bolt to the broken stud and unscrewed it. He said they do that all the time. Hope this helps.

bk

bcice, good idea, i've learned to do stuff like that too (figure out how to use leverage in a not so environmental friendly situation, that should be a good amount of leverage too, just wonder if he can get the screwdrivers into those holes... heck a couple of nails would work maybe.

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1970 SS396 AKA 454/4spd
My Chev-Hell Page (http://hometown.aol.com/jnkb2cool/home.html)
GOLD Member #783
Ft.Worth, Tx
(OO=ss=OO)

<BLOCKQUOTE>quote:</font><HR>Originally posted by bcice:
Bad. Can you get something like 2 very small screwdrivers down between the groves in the tap? If so, you may be able to put another screwdriver at 90 degrees between the two small ones and twist it out. Kind of like a barrel wrench. Man, I sympathize with you on this one. This sucks!<HR></BLOCKQUOTE>

Well I went home during my lunch hour and tried it. I thought it just might work. I couldn't use screwdrivers but I did use nails. Well, the tap must be really stuck, I stopped because I was about to twist off the nails. I am going to try chipping away one side of it tonight and see if that frees it up enough to turn. Mean while, does anybody know where I can get a tap extractor?

your local hardware store should have a good assortment of them.

Try Walton, Hansen-Whitney, Greenfield, they came to mind,

1BAD402
MSC Industrial Supply http://www.mscdirect.com/
Page 352 of their catalog list tap extractor kits or individual extractors.It shows a picture of one so you'll know what they look like.They are basically small oval shaped metal rods that fit into the flutes (chip clearance grooves) of the tap, and then a collar slips over them and you wind the broken tap out.Always use plenty of oil when tapping. Except for Spiral flute taps and form taps,most all taps will push the chip they cut forward into the hole you are threading.That is one of the things that jams up the tap and causes it to break.When you are tapping keep backing the tap out a half turn or so, this breaks the chip. Also back the tap out all the way and use air pressure to blow the chips out of the hole. For your broken tap,try using an air nozzle to remove the chips and small broken tap pieces out of the hole. Then very lightly,with a small punch and hammer hit the broken tap on the edge in the counter clockwise direction to see if it moves. If it does ,keep blowing the chips out with air and repeat the light taps till you get it out far enough to grab it with vise grips or pliers.(Not Fun) Hope this helps!

You can always try drilling it out with a left handed drill bit. Worked for me a couple of times.

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CFR.

I worked maintenance at Caterpillar for 10 years. One of the coolest tricks I ever saw a machine repairman do was removing a broken tap. He used an air scribe. the vibrations (high speed) allowed him to just walk it back out. Soak it with some penetrating oil first (Kroil is the best) and it should work great if you have access to a decent air scribe and air compressor. Good luck!