17 Practical Methods to Remove Broken Screw Taps | Removal Tips and Tools

Whenever you are faced with a broken screw tap, the first step is to determine the best way to remove it.

There are a few ways to do this, and each method has its own advantages and disadvantages.

In this blog post, we will discuss the different methods for removing a broken screw tap and provide some tips on how to make the process go more smoothly. Stay tuned!

What Are Screw Taps?

Screw taps are a type of tool that is used to create threads in a hole. They are usually made of high-quality steel and can be very expensive.

Screw taps come in a variety of different sizes and styles, and they can be used on a variety of different materials.

How Are Screw Taps Used?

Taps are usually used in conjunction with a die. The die is placed over the top and turned in the same direction as the screw tap. This cuts the thread into the material.

What Are Some Common Uses for Screw Taps?

Screw taps are commonly used in manufacturing and engineering applications. They can be used to create threads in holes that will be used to hold bolts or screws.

Taps can also be used to create threads on the outside of a piece of material, such as a pipe. This is known as “tapping.”

How Can I Remove A Broken Screw Tap?

There are a few different methods that can be used to remove a broken screw tap.

The best method will depend on the type of material the screw tap is made of and the size of the screw tap. Some common methods include using a drill, an EDM machine, a Dremel tool, or a chemical solution.

Heat can also be used, but it should be done carefully to avoid damaging the surrounding material.

17 Practical Methods to Remove Broken Screw Taps

1. Use a Die Grinder

If you have access to a die grinder, you can use it to remove the broken screw tap. First, you will need to use a drill bit to create a pilot hole in the center of the tap.

Next, attach the die grinder to the pilot hole and start grinding away at the tap.

You may need to go back and forth a few times before the tap breaks free. Be sure to wear eye protection while doing this, as small metal shavings will be flying everywhere.

2. Use an Oxy-Acetylene Torch

If you have an oxy-acetylene torch, you can heat up the broken screw tap and then break it free.

First, you will need to attach the torch to a tank of oxygen and acetylene. Next, turn on the gas and adjust the flame so that it is about four inches long.

Then, place the tip of the flame on the center of the broken tap and start heating it up.

After a minute or so, the tap should start to expand from the heat and then break free. Be sure to wear proper protective gear to avoid any injury.

3. Use a Hammer and Chisel

If you don’t have access to a die grinder or an oxy-acetylene torch, then you can use a hammer and chisel to remove the broken tap.

First, you will need to place the chisel on the center of the broken tap. Next, take a hammer and start hitting the chisel.

You may need to go back and forth a few times before the tap breaks free.

4. Use a Drill

If you have a drill, then you can use it to remove the broken tap. First, you will need to find a drill bit that is slightly smaller than the diameter of the tap.

Next, attach the drill bit to the drill and start drilling into the center of the tap. You may need to go back and forth a few times before the tap breaks free.

5. Use a Tap Extractor

Tap extractors are designed specifically for this purpose, making the job much easier. To use a tap extractor, first find the size that matches your tap.

Then, insert the extractor into the hole in the center of the tap and turn it clockwise until it’s tight.

Next, use a wrench to turn the extractor counterclockwise, and it should start to remove the tap.

6. Use a Hammer and Chisel

In this method, you will need to use a hammer and a chisel to create a groove around the circumference of the tap.

Once again, start by drilling into the center of the tap. Then, use the chisel to create a groove that is about 1/4″ deep.

Next, use the hammer to tap on the chisel and work your way around the circumference of the tap. Finally, twist the tap out with a pair of pliers.

7. Use an Easy Out Tool

Another method is to use an easy-out tool. First, drill a hole into the center of the tap using a drill bit that is slightly smaller than the diameter of the easy-out tool.

Next, insert the easy-out tool into the hole and turn it counterclockwise until the tap is removed.

8. Use A Left-Handed Drill Bit

The eighth method is similar to the above method, except that you will need to use a left-handed drill bit.

First, drill a hole into the center of the tap using a left-handed drill bit. Next, insert the easy-out tool into the hole and turn it clockwise until the tap is removed.

9. Use A Hammer and Screwdriver

Another way to remove a broken tap is to use a hammer and a screwdriver. First, find the end of the tap that is sticking out of the hole.

Then, place the point of the screwdriver on the end of the tap and strike it with the hammer.

The force of the blow will cause the tap to break, making it easier to remove.

10. Use A Hydraulic Jack

This method is similar to the above method, except that you will need to use a hydraulic jack.

First, find the end of the tap that is sticking out of the hole.

Then, place the point of the screwdriver on the end of the tap and strike it with the hammer.

The force of the blow will cause the tap to break, making it easier to remove.

11. Use Lubricating Oil

This is the most common and easiest method. Simply apply some lubricating oil to the threads of the broken tap and try to unscrew it.

The oil will help to lubricate the threads and hopefully allow the tap to turn more easily.

12. Use the EDM Machine

If the above method doesn’t work, you may need to resort to using an EDM machine. This is a specialized machine that uses electrical pulses to break down the metal of the tap so that it can be removed more easily.

13. Use a Dremel Tool

If you have a Dremel tool, you can use it to grind away at the broken tap until it is small enough to be removed by hand.

14. Use a Chemical Solution

There are a variety of chemical solutions that can be used to dissolve the metal of a broken tap.

These solutions should be used as a last resort, as they can damage the surrounding material.

15. Use Heat

Applying heat to the broken tap can sometimes expand the metal enough that it will become loose and can be removed by hand.

However, this method should only be used as a last resort as it can damage the surrounding material.

16. Use A Magnet

If the broken tap is made of ferrous metal, you may be able to remove it by using a magnet. Simply place the magnet on the broken tap and wait for it to adhere.

Once it is attached, you should be able to pull the broken tap out by hand.

17. Use Extractor Set

If you have an extractor set, you may be able to remove the broken tap by using one of the specialized extractors.

These sets usually come with a variety of different sizes and shapes of extractors, so you should be able to find one that will fit your particular situation.

Why Do Screw Taps Break?

Screw taps break for a variety of reasons. The most common reason is that the screw tap has become worn, and the threads can no longer grip the material it is cutting into.

Other causes include damaged taps, incorrect sizes, and improper installation.

The major reasons are explained below:

Poor Quality: The main reason the taps break is poor quality. The taps are made of high-quality steel, but they can still break if they are not properly taken care of.

Wear and Tear: Taps can also break down due to wear and tear. This is especially true if the taps are used frequently.

Over time, the threads on the taps can become worn and no longer grip the material correctly.

Damaged Taps: Damaged taps are another common cause of broken taps. The damage can be caused by a number of things, such as incorrect sizes, improper installation, or damage during use.

Incorrect Sizes: If the tap is the wrong size for the hole it is being used in, it can break. This is because the tap will not be able to grip the material correctly and will eventually slip out.

Improper Installation: Improper installation is another common cause of broken taps. If the tap is not installed correctly, it can become damaged and eventually break.

Improper Use: Improper use is another common cause of broken taps. Taps are designed to cut threads into a hole, but they can also be used to cut through other materials. If the tap is used to cut through something it is not meant to, it can become damaged and eventually break.

Lack of Lubrication: Lack of lubrication is another common cause of broken taps. Taps need to be lubricated on a regular basis to prevent them from becoming damaged.

Without lubrication, the taps can become dry and brittle, which can eventually lead to them breaking.

Dirty Taps: Dirty taps are another common cause of broken taps. If the taps are not cleaned on a regular basis, they can become clogged with dirt and debris.

This can eventually lead to the taps becoming damaged and breaking.

How Can I Prevent My Screw Taps From Breaking?

You can do a few things to help prevent your taps from breaking. First, make sure that you are using the correct size tap for the material you are working with.

Second, avoid using damaged taps. Finally, be sure to lubricate and clean your taps on a regular basis properly. This will help to keep them in good condition and less likely to break.

When removing a broken tap, it is important to take care not to damage the surrounding material.

A few different methods can be used to remove a broken tap, but some may damage the surrounding material if not used carefully. It is always best to consult with a professional before attempting to remove a broken tap yourself.

The Bottom Line

Taps can break for a variety of reasons, but the most common cause is wear and tear. Screw taps can also break if they are damaged, installed incorrectly, or used improperly.

To help prevent your screw taps from breaking, be sure to use the correct size screw tap for the material you are working with and avoid using damaged screw taps.

Also, be sure to lubricate and clean your taps on a regular basis.

Finally, if you need to remove a broken tap, be sure to consult with a professional before attempting to do so yourself.