Need advice on removing thermostat housing (1 Viewer)

[Pin_Head]

There are a couple of ways to deal with a broken tap stuck in a hole:

With oxy acetylene, heat the tap until red hot and then cut off the fuel and burn out the tap with oxygen. You may need to increase the O2 pressure to keep the burn going.

Without OA. Heat the tap with MAPP gas until red hot and then squirt water on it to rapidly cool it. Then smack the cooled tap with a drift punch and a hammer. It should shatter like glass. This wont hurt steel or cast iron bacause they won’t get hot enough to harden and get brittle.

Grinding it out with a diamond burr might work, but it will be slow going and it is hard to keep it centered and not oval out the hole.

 

[rstoddard]

I got it out using diamond drill bits and a rotary dremel. Managed to loosen it enough after drilling it and turning it, that I was able to eventually get it turned back out.

It was broken too deep to weld, and it was too stuck to turn with an extractor tool. It was just a case of working at it for a couple hours until I got enough pieces out that I was able to get it to turn out.

That’s a mistake and problem you never want to repeat!