Broken tap

[JustJohn]

So here's where I am:

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1/4-20 tap snapped off about 1/2 deep. It will rotate about 1/4 turn. I tried a tap extractor and the pins sheared twice. Can't put enough load on it. This is on my trans crossmember, of course the very last thing I was doing. I haven't tried any other methods yet. Waiting for some sound advice before I go nuclear on it.
I'd like to fix it now but realistically I can wait until the body is off in another month or so.

[andrewb70]

The only thing I can think of is welding a bolt to it.

Andrew

[raustinss]

compressed air while rotating it ???? ....also try using some heat to maybe free stuff up .

[JustJohn]

Since the crossmember is relatively easy to take off at this point, I'm going to try TIG welding to the end of it as the next, least destructive step. Should have the correct filler rod by tomorrow.

(Part of me wants to just bash it with a punch and hope it shatters.)

[JustJohn]

Spoke to one of our machinists at work and he gave me another non-destructive approach. Have to take the cross member off anyway so trying a drill press option.

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[JustJohn]

And this is done. Ted (machinist) gave me the Omega drill kit and a couple of old carbide end mills in the right size. It would have been even cleaner on a mill but the drill press got me where I needed to be. Started the hole with the carbide mill and blew through the rest of the tap with the Omega bit. Probably put a spot of weld on it, re-drill and tap to finish it out.

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