Broken tap in head (n54)

Stevo585

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Dec 16, 2022
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During the plugging of my of head ports the 10/32 tap snapped off in the head.

Anyone have any tool recommendations for extractions? I’ve tried drilling but the tap is hardened and I’m not making a dent.

(Tried using pliers but it broke clean off flush with the head.)

Thanks,
 

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tobi01

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Nov 17, 2022
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I would try to grind (preferbly with a dremel or other multitool and small grinding disk ) a slot and use a flat screw driver to turn it out. If it does not turn, apply decent heat with a heat gun and carefully hammer on it to achieve a little clearance.
 

Stevo585

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Dec 16, 2022
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I tried cutting a slot and turning it with a flat head but it cracked off.

I’ll try adding some heat just to see if I can get it to relax some.

Thanks for your input!
 

wheela

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Can you get the tips of a needle nose pliers between the flutes and inside of the hole to twist it out?

I saw another thread here recently where somebody mentioned they snapped the tap off like this (among a slew of other problems), but I can't find the thread, or recall how he got it out🙄
 

Stevo585

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Dec 16, 2022
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For size reference the holes between the flutes are smaller than a bobby pin... I'll get a picture of what it looks like now.
I saw they make "tap extractors" but I have not been able to find one that is this small.

If I can't get this out I'm not sure what my options are, JB weld the flute gaps?

Yeah a simple tap job turned into a nightmare.
 

wheela

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For size reference the holes between the flutes are smaller than a bobby pin... I'll get a picture of what it looks like now.
I saw they make "tap extractors" but I have not been able to find one that is this small.

If I can't get this out I'm not sure what my options are, JB weld the flute gaps?

Yeah a simple tap job turned into a nightmare.
Shoot, I didn't realize it was that small. I find that post I was thinking of (attached), looks like he used a tap extractor
 

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SLOWESTN54

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Check the valve cover to see If something interferes with it. I think there's a hole of sorts in that area.
 

Stevo585

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Dec 16, 2022
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@SLOWESTN54 I have the vtt billet valve cover so there are no holes.

The tap going in at a 45 degree angle doesn’t help either…

It’s flush with the head so I’m not worried about it not sealing, I may just pack it with ole rtv.
 

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SLOWESTN54

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@SLOWESTN54 I have the vtt billet valve cover so there are no holes.

The tap going in at a 45 degree angle doesn’t help either…

It’s flush with the head so I’m not worried about it not sealing, I may just pack it with ole rtv.
Is this case put some loctite down the hole and call it 👍 that’s a Diy plug
 

Torgus

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@SLOWESTN54 I have the vtt billet valve cover so there are no holes.

The tap going in at a 45 degree angle doesn’t help either…

It’s flush with the head so I’m not worried about it not sealing, I may just pack it with ole rtv.

When I did mine I installed the plugs with locktite and then filled the rest of the hole up with rtv. You should be fine with RTV or similar.
 

SLOWESTN54

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When I did mine I installed the plugs with locktite and then filled the rest of the hole up with rtv. You should be fine with RTV or similar.
Was I supposed to rtv the hole? Oh wait I’m pretty sure we used a Npt tap on my head with a Npt plug. Along side red loctite
 
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Torgus

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Was I supposed to rtv the hole? Oh wait I’m pretty sure we used a Npt tap on my head with a Npt plug. Along side red loctite

There is no 'real' need. I had a tube lying around and I tapped deep enough there was room for RTV on top after applying loctite to the threads.


Granted we all technically should have used NPTF threads:


Like NPT connections, tapered threads hold NPTF connections together. And these connections are solid and tight. Crushing the thread crests fills the potential spiral leak path in NPT connections. Filling this leak path is why NPTF connections do not generally need thread sealants and why NPTF is considered a dryseal connection.


Technically Locktite can be used also as a thread sealant. So either way everyone should be fine ;)
 

Stevo585

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Dec 16, 2022
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Update:

I purchased a tap remover tool and it ended up breaking first use. There is nothing small enough to fit between the flutes of the tap without breaking.

The Tap ended up breaking off deeper into the hole and had no other choice but to fill it with high-temp JB weld.

Not what I wanted, but I had no other options.

Thanks for the insight everyone!