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Old 07-30-2013, 09:41 AM   #1
Tom Vogel
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Removing a small tap

Yesterday I broke off a 10-24 tap that was 5/8" into the cast iron portion of one of my spindles. The tap snapped off 2 threads down into the hole. Crap...
I remember reading on the Practical Machinist Forum where a guy said he used his tig torch to build up the tap with .040 stainless rod. He used a .040 tungsten and a 1/2" gas lense to build up the tap to about 1/4" above the hole. Then he placed a small washer and nut over the built up tap and welded the nut to the tap. Then he backed it out with a wrench.
I thought ,"that'll never work", "that tap is in there tight and its tool steel".
I was wrong, it worked, see my pic.


I know this will probably get moved and thats fine, but I thought it was a neat trick for you guys to catalog in your mind for future use.
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Old 07-30-2013, 03:55 PM   #2
Classic Heartbeat
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Re: Removing a small tap

Great Job Tom!! Great piece of info! WES
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Old 07-30-2013, 04:13 PM   #3
68gmsee
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Re: Removing a small tap

Pic? Attachment not working for some reason.
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Old 07-30-2013, 05:59 PM   #4
SS Tim
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Re: Removing a small tap

Not bad....
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Old 07-30-2013, 08:00 PM   #5
Tom Vogel
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Re: Removing a small tap

Thanks for posting my pic Tim. I emailed it to myself hoping for an automatic resize... didnt work, ended up in a zip file.
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Old 07-30-2013, 08:16 PM   #6
TBONE1964
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Re: Removing a small tap

I have had several taps break off in holes and I have always had to use a center punch with a nice dead blow or ball peen hammer and just break them apart until they fall out of the hole they broke in. Face shield is highly recommended for this. I don't have the luxury of a tig so that would not work in my case. Great idea if the tig is available. The nice thing about tool steel is that it is on the brittle side and will break into smaller pieces if need be.
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Old 07-30-2013, 08:18 PM   #7
67swb72klb
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Re: Removing a small tap

nice job an old friend of mine has a welding shop i saw him do it many times works perfect
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