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Thread: Removing a broken off tap
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5th Aug 2021, 08:48 PM #1Senior Member
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Removing a broken off tap
While trying to repair my lathe, I’ve broken off an m4 tap in this shaft. Can’t think of any other ways to remove it, I’ve tried drilling it out on the mill, tried punching it, heating the shaft, it’s in there. Any ideas? 899C4B07-CDBD-4499-880D-9EC0BBF8E6A4.jpeg
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5th Aug 2021, 09:00 PM #2Diamond Member
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EDM or drill it out with a carbide endmill.
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5th Aug 2021, 09:03 PM #3Most Valued Member
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How important is the shaft?
Can you drill through from the other side?
Can you make a new shaft?
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6th Aug 2021, 06:28 AM #4Senior Member
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6th Aug 2021, 06:33 AM #5Senior Member
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It’s the shaft that slides the gear cluster across to engage the cross dlide feed and the half speed carriage feed, I’ve never been happy with it always been clunky to use. Turns out there’s a projecting machine screw inside that was catching on a gear shoulder as well so I’m glad I pulled it apart to find that.
I ended up drilling and tapping a grub screw into the end of the handle block with a small drill indent into the shaft and it works nicely. Thanks for your ideas
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19th Aug 2021, 01:57 PM #6New Member
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Just in case anyone else gets stuck-
Years ago as an electrical fitter at a steam boiler factory this kind of fun was gong on all the time- an extractor with good heat and lube usually took care of things...
The first one pictured was good for brute force, the second worked well for finer, smaller accidents.
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19th Aug 2021, 07:54 PM #7Philomath in training
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You know, the problem with extractors like that is that I never break big taps. It's always the small ones, and sometimes even spiral flute.
Michael
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19th Aug 2021, 08:29 PM #8Most Valued Member
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If there's a bit of the tap protruding out of the shaft, try plug welding a nut to it. (That is through the inside of the nut.) Sometimes the heat from welding is sufficient to shrink the tap enough to allow it to come out.
HTH,
KrynTo grow old is mandatory, growing up is optional.
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19th Aug 2021, 09:54 PM #9Philomath in training
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Tried that one too...
Michael
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20th Aug 2021, 12:33 AM #10
Hi Guys,
Somewhere kicking about on one of my HDD's I have a design for a DIY EDM machine ! It would make a nice project, I'll see if I can find it and dig it out, assuming that there is any interest in building one.
It would be ideal for the removal of broken taps, drills etc.Best Regards:
Baron J.
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20th Aug 2021, 12:39 AM #11Most Valued Member
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Thanks John, I'd certainly be interested in looking at building a unit.
Thanks again
KrynTo grow old is mandatory, growing up is optional.
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21st Aug 2021, 03:14 PM #12Tool addict
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I'd be interested in those plans!
I still think of when an old workplace of mine had an EDM machine come through (we did some secondhand machinery sales), and how I wished I had an excuse (and the funds) to buy it. A diy unit would be somewhat more storable than a two-ton monster
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29th Aug 2021, 07:47 PM #13
Diy edm !
Hi Guys,
Thanks for the replies showing interest in a DIY EDM Machine. I've spent several unsuccessful days going through my backup HDD's, looking for the information that I originally downloaded from the internet ! I've also done a web search for the information. Of the half dozen or so that I found, non are of the original design. However most do seem similar.
From memory the design that I recall used an audio amplifier and a modified loudspeaker along with a square wave oscillator to generate about 20Khz or so for the head movement. The spark power supply was around 60 volts or so with a boost capacitor, though I don't recall the actual circuit. The feed had a motor driving a leadscrew, but again I don't remember how it was controlled.
At the time it was one of those things that grabbed my attention and then filed away for future use and forgotten about until it was mentioned earlier.Best Regards:
Baron J.
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30th Aug 2021, 09:57 AM #14
I just had a google of broken tap removers like in Apple sheds post, when I was looking at what sizes .there was I saw this.
Note:
1.This kind of extractor is only suitable for the broken tap which is not too tight.
2.If the tap is too tight, it will break the claw easily.
3.The smaller the extractor, the easier to break, the lower the success rate.
Ratty 05/2004 -05/07/2010 COOPER 01/08/1998-31/01/2012
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30th Aug 2021, 06:42 PM #15
DIY EDM, stepper driver.
Hi Guys,
Whilst trawling through my backup HDD's I found this picture which is I think part of the EDM drive circuit. I've not built this but I don't see any reason why it should not work OK .
cheapstep_r1.jpg
Looking at the drawing date August 2007 it gives an idea of how long ago this was published. I can't find this on the internet so I assume that its gone for good. I had hoped that it would lead me to finding the rest of the information on the DIY EDM machine.
I'll keep looking !Best Regards:
Baron J.
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