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I was working on the bike and removed two cap screws mounted to the frame. They didn't want to go back in right so I tried following the threads with a tap. The tap broke off in the frame. As you can see, it broke off flush with the frame and at an angle so I can't grab it and twist it out.
I can tell you from experience that you've got a big problem. First, I would ask if anything critical bolts on there. If not, leave it be.
If it does, you have precious few choices.
Virtually impossible to drill.
Chip it out piece by piece with a hardened punch/chisel. Absolutely positively wear eye protection. This will take time and patience. Looks to be maybe a 1/4" tap, maybe 5/16". If it's that small......all I can say is "Damn. I'm glad I'm not you."
Another way is to take it somewhere that does Electrical Discharge Machining (https://en.wikipedia.org/wiki/Electr...arge_machining) and have it burned out. Most likely it'll damage the threads too. But then they're already damaged.
Once you get it out, you will have learned an extremely valuable lesson. DO NOT get over zealous chasing or tapping threads, and always use cutting oil.
I used to break taps off pretty frequently when I was a young and impatient machinist. I rarely ever break one now. I just don't try to force taps anymore, and I always buy good taps.
Last edited by Mike Lawless; Jun 22, 2016 at 11:05 AM.
You could try a carbide tipped drill, like a masonry drill. Or a diamond tipped tool in something like a dremel. Work slowly and patiently. Might try heating the area with a heat gun. Drill a little, and try to knock out a little of teh tap until it goes away. Good luck, that's really a hard one.
you might try these. I have never used them but i have friend that that has used them successfully. They are available from McMaster-Carr.
Tap Extractors
Remove broken taps and save threads. Extractors have hardened steel fingers that fit in the straight flutes of a broken tap so you can remove the tap without damaging the workpiece threads. Use them on hand taps and taps for through-holes. They're made of tool steel and have a square shank that fits standard tap wrenches.
Tap Extractors
Use a dremel and a carbide "burr". Start in the center & grind it out from the inside out. Go slow & be patient, it's going to take a while.
You'll probably have to redrill and tap to the next size up.... a metric thread may be the closest next step.
Good luck.
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It's not a critical bolt, which is good (I guess). It's a 1/4" tap but it's location makes it hard to get anything in there. I can probably get to it with a punch...how much pressure is needed to chip/break it?
I appreciate the reply!
Originally Posted by Mike Lawless
I can tell you from experience that you've got a big problem. First, I would ask if anything critical bolts on there. If not, leave it be.
If it does, you have precious few choices.
Virtually impossible to drill.
Chip it out piece by piece with a hardened punch/chisel. Absolutely positively wear eye protection. This will take time and patience. Looks to be maybe a 1/4" tap, maybe 5/16". If it's that small......all I can say is "Damn. I'm glad I'm not you."
Another way is to take it somewhere that does Electrical Discharge Machining (https://en.wikipedia.org/wiki/Electr...arge_machining) and have it burned out. Most likely it'll damage the threads too. But then they're already damaged.
Once you get it out, you will have learned an extremely valuable lesson. DO NOT get over zealous chasing or tapping threads, and always use cutting oil.
I used to break taps off pretty frequently when I was a young and impatient machinist. I rarely ever break one now. I just don't try to force taps anymore, and I always buy good taps.
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Broken tap
