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  1. #1
    Join Date
    Jul 2011
    Location
    Berowra Waters
    Posts
    121

    Default Removing a broken off tap

    While trying to repair my lathe, Iíve broken off an m4 tap in this shaft. Canít think of any other ways to remove it, Iíve tried drilling it out on the mill, tried punching it, heating the shaft, itís in there. Any ideas? 899C4B07-CDBD-4499-880D-9EC0BBF8E6A4.jpeg

  2. #2
    Join Date
    Mar 2014
    Location
    South of Adelaide
    Posts
    901

    Default

    EDM or drill it out with a carbide endmill.

  3. #3
    Join Date
    Jun 2007
    Location
    sydney ( st marys )
    Age
    62
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    4,706

    Default

    How important is the shaft?
    Can you drill through from the other side?
    Can you make a new shaft?

  4. #4
    Join Date
    Jul 2011
    Location
    Berowra Waters
    Posts
    121

    Default

    Quote Originally Posted by snapatap View Post
    EDM or drill it out with a carbide endmill.
    yeah I tried but the tap is tungsten so it just took the ends off the cutter quick smart, thanks for the suggestion though at least I know I was on the right track.

  5. #5
    Join Date
    Jul 2011
    Location
    Berowra Waters
    Posts
    121

    Default

    Quote Originally Posted by pipeclay View Post
    How important is the shaft?
    Can you drill through from the other side?
    Can you make a new shaft?
    Itís the shaft that slides the gear cluster across to engage the cross dlide feed and the half speed carriage feed, Iíve never been happy with it always been clunky to use. Turns out thereís a projecting machine screw inside that was catching on a gear shoulder as well so Iím 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

  6. #6
    Join Date
    Aug 2021
    Location
    Huon Valley
    Age
    52
    Posts
    6

    Default

    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.



  7. #7
    Join Date
    Oct 2011
    Location
    Norwood-ish, Adelaide
    Age
    56
    Posts
    5,930

    Default

    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

  8. #8
    Join Date
    May 2011
    Location
    Murray Bridge S Aust.
    Age
    69
    Posts
    4,904

    Default

    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,
    Kryn
    To grow old is mandatory, growing up is optional.

  9. #9
    Join Date
    Oct 2011
    Location
    Norwood-ish, Adelaide
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    56
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    5,930

    Default

    Tried that one too...

    Michael

  10. #10
    Join Date
    Sep 2012
    Location
    York, North Yorkshire UK
    Posts
    4,978

    Default

    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.

  11. #11
    Join Date
    May 2011
    Location
    Murray Bridge S Aust.
    Age
    69
    Posts
    4,904

    Default

    Thanks John, I'd certainly be interested in looking at building a unit.
    Thanks again
    Kryn
    To grow old is mandatory, growing up is optional.

  12. #12
    Join Date
    May 2008
    Location
    Perth
    Posts
    235

    Default

    Quote Originally Posted by BaronJ View Post
    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.
    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

  13. #13
    Join Date
    Sep 2012
    Location
    York, North Yorkshire UK
    Posts
    4,978

    Unhappy 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.

  14. #14
    Join Date
    Aug 2008
    Location
    Tennant Creek, Aust
    Age
    59
    Posts
    520

    Default

    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

  15. #15
    Join Date
    Sep 2012
    Location
    York, North Yorkshire UK
    Posts
    4,978

    Thumbs up 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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