Tap broken off in exhaust manifold head stud hole...

Cool stories.

 

Just trying to help the guy out. Obviously you're a little self righteous about it, so tell me what is it going to hurt to try? Weld won't stick and he's out a couple minutes of trying. Or it works and he can clean out the hole and be on his way. Beats hours and hours of attempting to shatter it. I've personally seen it work on extractors, which are usually made out of the same metal as a tap generally hi-speed steel. So far you haven't helped out at all, so tell me how you'd get it out so maybe he has a solution.

 

So far I have helped out. I suggested a bit made of carbide or diamond to grind it out, or to freeze it and shatter it.

 

You suggested he use an expensive tool he doesn't even have, with skills he doesn't even have, on a hole too deep that even a professional would likely say "use another method." Nice extrapolation. It's not hard to find a carbide or diamond-tipped bit, nor is it hard to find liquid CO2 or nitrogen.

 

So he's going to tow his car to a welder? I bet that's free. I bet the welder charges nothing, too. There are no specific welding services. Maybe people like you know people who weld, but you can't just look up a welder in the yellow pages. I still wouldn't bother or trust welding it. Give me a break.

 

i am a machinest by trade..it will break pretty esay on aluminum,because the

metal is soft,so it will bind up,so when you back out it will bind up and lock up..

and if you forces it,it will snap..frist of with soft metals,the less flutes the tap

has, the better it will cut,because there is more relief.so a 2 fulte tap would be

good.so the hearder the metal the more flutes,like a 3 or 4 flute tap.

now dose not matter what you will be tapping, always go in 1/4 of a turn in,

then 1/4 of a turn out,thats the way tapping works,when you turn in it cuts,so

when you back it out it will break the metal chips,so you will not get any binding.

always use some good lube..

 

Pulling the head would cost more than towing... Keep trying.

 

At this point unless he is willing to risk his motor, he's going to have to pull the head anyways. Metal shavings in the engine is not a good thing, especially in the oil.

 

I just fixed a head with a broken tap and lets say it involved drilling the enitre hole much bigger. Tapping it to a 1/2 bolt, running a 1/2 bolt into the head, cutting it flush, and then drilling a new hole in the new bolt and tapping it... All after about 2 hours of messing with the head getting the old tap out. BUT mine job was way worse than your looks like.

 

yes, i will agree with you on that,but maybe he wen't in too deep or used the wrong pitch tap, etc..

anyway,dose anyone know how manny flute tap he was using..its hard to tell from pics..

 

yes 8m x 1.25, no arguing here..all good.

how many flutes was the tap,did you try a tap exstrator?

 

I had good result removing a broken stud just using a reverse flute drill bit. I know this is a broken tap but nevertheless...

 

Now you drill out the hole and tap it for a larger stud. You'll have to drill the hole out on the manifold too. I'd pull the head drilling and tapping a larger hole is going to create alot of shavings.

Also wasn't trying to argue, just supply a solutikon that apparently I had to defend for some odd reason.

 

I have welded to a tap many times. So that is the first thing I would try. Once you weld to it get the area around the tap hot then try to turn it out. Really isnt that hard to do. Still confused as to how you broke it off in there.... I tapped all of mine with a tap on my drill, maybe I should re consider that next time.....