#5 galley plug...tap broke...

[HopLite]

So my OEM #5 galley plug blew spewing oil everywhere.

No big deal...I can just tap with a M8x1.25.

I've tapped about 8 threads, being VERY careful to stop every 1/2 turn.

*SNAP* the tap broke (also appx 8 threads deep)

What to do?

I see 2 options:
(1) clean-up exposed tap with dremel and slather with JB weld.
(2) pull engine, drill out tap with carbide. (Didn't look like there was room for a drill without pulling the engine...)

Please note, this is my daily driver. I'm not about to pull the engine. Any other thoughts besides (1) above?

Humbly, Hoplite

 

[Dynosoar]

Go buy a tap extractor and pull out the broken piece.


Dynosoar

 

[3_puppies]

Go buy a tap extractor and pull out the broken piece.


Dynosoar

X2... or sometimes needle nose pliers will work

 

[Pighead]

The JB weld will probably hold. Give it a try.

 

[Mr. Toad]

I'd make some kind of 2-pronged tool, shove the prongs down the tap flutes, and back the tap out.

Or you could use a punch (nailset, etc.) and tap it with a hammer to turn the tap anticlockwise to back it out.

 

[rchalmers3]

Tap tools are very brittle. You can shatter the broken off piece in the hole using a punch and hammer. Then continue...... with a new tap! Be sure to clean up all the shrapnel afterwards!

Rick

 

[bigbrown]

i did the same thing.

i tried the jb weld idea filling around the broken tap. it worked for a while, but then began leaking again.

i had to pull the head so i had the machine shop remove it and fix it correctly. done.

 

[HighPlainsDrifter]

While we're on the subject..... I followed these directions and have had no problems with it at all. Works like a champion. The whole rifle bore swab is a really good idea.

Welcome to ROCKCRAWLER.COM (Land Cruiser Q&A, March 15th, 1998)

 

[lovetoski]

While we're on the subject..... I followed these directions and have had no problems with it at all. Works like a champion. The whole rifle bore swab is a really good idea.

Welcome to ROCKCRAWLER.COM (Land Cruiser Q&A, March 15th, 1998)

Those are the instructions I followed. Worked fine. I did worry about breaking the tap though...glad it didn't happen. I wonder if the quality of the tap is an issue? Is a cheap tap more brittle?

 

[Elbert]

If the tap broke below the level of the hole you are going to have some real problems. I think your only option would be to remove the head and do the machine shop trip. If the tap broke above the level of the hole, such that you have some the tap material to work with then you might be able to remove it using one of the ideas suggested above, but I doubt the tap will come out that easy given that its hardned metal, worth trying though. Be very careful if you try an ease-out or other simaler tool...if you apply too much pressue to one of the small ease-outs they will break without warning too and you'll really have a problem. I don't have any magic solutions, other than to say if the tap is broken off below the surface level of the hole, then I would remove the cylinder head and find a good machine shop.

 

[Rob Faucett]

x 3 on tap extractor. Something like Walton Tap extractors how to use, sets, individual extractors , parts and fingers

Good luck!

 

[rchalmers3]

Pulling the head is your option of couse. But it dosen't have to be plan A, it can be plan B or C.

Trying to extract the tap end is plan A. Hit the sucka with a small punch and see if you can shatter it. Don't be a panty waiste about putting the hurt on it. If you shatter it, pull out the pieces and continue on with your self remedy on the oil gusher.

Usuall a tap is too stuck to back out with another tool. The thing is wedged in the new threads it was cutting and is therefore a good candidate to receive some punches.

EDIT: Breaking the tap is what a machine shop will do. Ask them! They don't have any special magic for removal of hardened tooling either.

Go get 'em!

Rick

 

[HopLite]

Thank you for all of the responses.

Plan A: I have a Walton tap extractor being shipped to me...should have it Wed. Until then, I'm the guy cranking around on his road bike :]

Plan B: JB weld for the short term...until I learn how to take off the head.

Plan C: Use the rifle swab and hit the pi$$ out of it (thank you for the reassurance that I shouldn't be afraid to thump it...)

Plan D: Take the head off, bring it into the R&D shop at work and try not to break their machines. But hey, I'll have learned how to take the head off!

Plan E: DIESEL!!!

Just have to wait and see!

 

[Rob Faucett]

Invert your list!

 

[Heartworm]

Could you stick a small Dremel stone in there and grind it up??

 

[HopLite]

Small dremel stone......worth a try. I also have a tiny carbide that might work. Good suggestion. Might give 'em a try after the tap extractor...

 

[Mr. Toad]

Could you stick a small Dremel stone in there and grind it up??

Nope.

 

[Randy88FJ62]

Still stuck on this?

 

[cruiserbrett]

some machine shops. good ones have an electro-arc tool that is made exactly for the process of removing hardened tools from cast iron, aluminum etc. It uses a really expensive electrode(tunsten), and an electric current to burn the metal out. Seen them use it, and its pretty cool. It doesnt leave all that clean a hole in smaller situations, but you have to drill and tap the remaining hole anyhow.

EDIT: Breaking the tap is what a machine shop will do. Ask them! They don't have any special magic for removal of hardened tooling either.

Go get 'em!

Rick

 

[HopLite]

Today is Wednesday...meaning I'll be receiving my brand new Walton tap extractor. I'll update tonight...

I did talk to a few guys in the tool room/R&D shop where I work...apparently we typically burn-out all of our stuck taps (even in very small holes). But, then again, that means I'll have to remove the head which for some may not be a big deal, but I'm a rook and hope not to get that deep into this. It is, however, nice to know there is a definitive solution regardless of how difficult it may be to get there (unfortunately, that means this can be solved with something other than a diesel conversion).

So stay tuned and hopefully the wrench turning will be putting things back together and not taking things further apart.