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Re: breaking off a tap?!

To: nicholas harteau <nrh@ikami.com>
Subject: Re: breaking off a tap?!
From: Eric Murray <ericm@lne.com>
Date: Mon, 3 Mar 2003 17:27:39 -0800
On Mon, Mar 03, 2003 at 06:15:20PM -0600, nicholas harteau wrote:
> 
> I can't even believe it.  I was tapping some threads into what basically
> amounts to aluminum stock (an aftermarket upper tailgate for my truck)
> and I broke the lovely tap off inside the pillar!
> 
> Not only that, it's a brand new tap.
> 
> The break is on a pretty extreme angle.
> 
> I have no idea how to get this out besides take it to a machine shop and
> pray.  Any ideas?

Put a steel nut with the appropriate sized hole over the hole
in the aluminum, and use a mig welder weld the nut to the end
of the tap.  

I have not tried this one myself, but others have reported success with it.

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