How To Remove A Broken Thread Tap

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

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.

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 in 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.

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 in 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.

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.

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.

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.

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.

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.

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.

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.

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.

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.

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.

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.

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.

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.

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.

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Why Do Screw Taps Break?

Screw taps can break for several reasons. Below are the major causes:

How Can I Prevent My Screw Taps From Breaking?

You can significantly reduce the risk of breaking screw taps by following these best practices:

1. Use the Correct Size Tap
   • Ensure the tap matches the material and hole dimensions to prevent slipping or excessive stress.
2. Inspect for Damage
   • Regularly check your taps for signs of wear, cracks, or other damage before use.
3. Proper Installation
   • Follow correct installation procedures to avoid unnecessary strain on the tap.
4. Lubricate Regularly
   • Use appropriate lubricants to keep taps smooth and prevent brittleness.
5. Clean After Use
   • Clean taps thoroughly to remove dirt, debris, or metal shavings that could cause clogging.
6. Avoid Misuse
   • Only use taps for their intended purpose (e.g., cutting threads, not other materials).

Tips for Removing Broken Taps

If a screw tap breaks, removing it carefully is essential to avoid damaging the surrounding material. Here are some steps to follow:

1. Use Proper Tools
   • Specialized tools like tap extractors or screw removal kits are ideal for removing broken taps.
2. Work Gently
   • Apply steady, gentle force to avoid further damage to the material or tool.
3. Consult a Professional
   • If unsure, seek professional assistance to ensure safe and effective tap removal.

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