Everyone has done it or will do it. Today was my turn.

[Deleted member 46119]

I broke a 6-48 tap off in a blind hole.

It's about 3 threads in.

Been making small stuff for 40 years, mostly radio control 4-40. Never broke a tap before.

Suggestions?

 

[Greyfox]

I broke a 6-48 tap off in a blind hole.

It's about 3 threads in.

Been making small stuff for 40 years, mostly radio control 4-40. Never broke a tap before.

Suggestions?

Not sure if this wil apply to the orientation of your break, but I had this happen. Enough of the broken tap was showing to allow me to cut a screwdriver slot in the tap with a Dremel diamond wheel cutter. With the help of some liquid wrench I was able to back it out with a screwdriver.

 

[Deleted member 46119]

Not sure if this wil apply to the orientation of your break, but I had this happen. Enough of the broken tap was showing to allow me to cut a screwdriver slot in the tap with a Dremel diamond wheel cutter. With the help of some liquid wrench I was able to back it out with a screwdriver.

Thank you. It's too low for that.

 

[Greyfox]

That makes it tougher. Before I was able to get mine out, someone recommended that I try this product;

OMEGADRILL

 

[338Rocket]

Omega drills work well, but a carbide ball endmill or carbide drill will get through hss taps easily, especially small ones. Both options require a very rigid setup (mill with a collet).

 

[Deleted member 46119]

I'e got an OmegaDrill and 1/8 Carbide Ball End Mill on the way.

Thanks everyone.

 

[338Rocket]

I think I would have went 3/32" unless you are planning on going up to #8 screws.

1/8" is larger than the drill size for 6-48, and you need to factor in some wobble. I like to use a bit that is just larger than the center of the tap, so it leaves just the flutes behind.

 

[Deleted member 46119]

I think I would have went 3/32" unless you are planning on going up to #8 screws.

1/8" is larger than the drill size for 6-48, and you need to factor in some wobble. I like to use a bit that is just larger than the center of the tap, so it leaves just the flutes behind.

Yup. Cancelled the order.

Taking some advice. I made a punch out of O1, hardened and sharpend. Then chipped away at it. Especially the center of the flutes. Pieces just kept coming off. Eventually all of it broke. A little picking and it's clear and the hole is saved.

 

[Deleted member 46119]

Thanks to everyone for the help.

 

[338Rocket]

Glad it worked out!