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  #1  
Old 01-12-2019, 06:43 PM
jfisher jfisher is offline
 
Join Date: Jan 2018
Location: C27
Posts: 28
Angry Broken Tap in rollbar - UGH!!

Major bummer tonight.

Step 4 of 38-03 calls for tapping 6-32 threads through the rear window into the rollbar. Going well until number 8 when I managed to snap off the tap. RRRR!

Not a happy camper. Been reading lots of google searches, but can't find anything that would work with plexi on top of aluminum.

The tap is broken flush with the top of the plexi about halfway down.

Couldn't find anything in the forums for broken taps. Anybody got any ideas??

I'm stuck.
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Manchester, IA
RV-14A 140411 Began Jan 2018
Tail kit and QB fuselage done
Finish kit done
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  #2  
Old 01-12-2019, 06:48 PM
ty1295 ty1295 is offline
 
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Location: Jeffersonville, IN
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Can you use a center punch and shatter it/push it thru? I assume hole is thru hole.
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  #3  
Old 01-12-2019, 06:55 PM
rnewcomb7797 rnewcomb7797 is offline
 
Join Date: Mar 2015
Location: Ft Leonard Wood, MO
Posts: 15
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same thing happened to me but the plexiglass cracked too. I had to order new plexiglass and start over. I ground off the broken tap flush with rollbar cause i couldn't remove it. Drilled a new hole next to it. The second time I removed the plexiglass before tapping. That was a hard and expensive lesson learned.
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  #4  
Old 01-12-2019, 07:16 PM
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scard scard is offline
 
Join Date: Jun 2005
Location: Cedar Park, TX
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Stop, pause, don't make any sudden moves. It will be there tomorrow and the next day.

From what it sounds like, the tap isn't actually broken off inside what you were tapping. Any such event is definitely time consuming, but this is a little "craftsmanship" test that you can absolutely succeed at.

Noodle it long enough and I assure you that you will be victorious. Sometimes it is even acceptable, as a very last resort, to complete a "fix" by abandoning in place and moving on.
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  #5  
Old 01-12-2019, 07:45 PM
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tomkk tomkk is offline
 
Join Date: Apr 2014
Location: Port Orange, Fl
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That happened to me on an RV-12 canopy. I had a small cone shaped grinding tool for my Dremel. I used the tip of that to grind the broken tap down below the upper surface of the Plexiglas. Doing that ended up heating the plexi enough so a helper could actually gently raise the plexi off of the broken tap. I ended up with a hole slightly larger than the others but that wasn't a problem.
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  #6  
Old 01-12-2019, 07:50 PM
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Steve Melton Steve Melton is offline
 
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Location: Cincinnati, OH
Posts: 2,119
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one option, cover hole with RTV and move on. I have one like that. I notice it once in awhile and smile now.
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Cincinnati, OH
RV-9A, Tip-up, Superior O-320, roller lifters, 160HP, WW 200RV, dual impulse slick mags, oil pressure = 65 psi, EGT = 1300F, flight hours = 700+ for all

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  #7  
Old 01-15-2019, 04:30 PM
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Erimo Erimo is offline
 
Join Date: Jul 2015
Location: Marcoussis, France
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Quote:
Originally Posted by jfisher View Post
Major bummer tonight.

Step 4 of 38-03 calls for tapping 6-32 threads through the rear window into the rollbar. Going well until number 8 when I managed to snap off the tap. RRRR!

Not a happy camper. Been reading lots of google searches, but can't find anything that would work with plexi on top of aluminum.

The tap is broken flush with the top of the plexi about halfway down.

Couldn't find anything in the forums for broken taps. Anybody got any ideas??

I'm stuck.
Mine :



With the other tap's end, a 8-32 nut and three little bits of piano string:





and it came out slowly. (Don't forget some cutting oil)
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  #8  
Old 01-15-2019, 04:35 PM
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JonJay JonJay is offline
 
Join Date: Jan 2007
Location: Battleground
Posts: 4,193
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Looks like a cheap o three flute tap ?
If there is a lesson to be learned here.....
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  #9  
Old 01-15-2019, 04:40 PM
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catmandu catmandu is offline
 
Join Date: Dec 2005
Posts: 770
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Well, I'll vote for a lesson to be learned: by me! Cheapo tap or not, that is one goodly tool to put in my noggin' bag, time to invest in some piano wire of varying diameters. Thanks!
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Maryland's Eastern Shore
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  #10  
Old 01-16-2019, 01:52 PM
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Erimo Erimo is offline
 
Join Date: Jul 2015
Location: Marcoussis, France
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Quote:
Originally Posted by JonJay View Post
Looks like a cheap o three flute tap ?
If there is a lesson to be learned here.....
Not so cheap yet !
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