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  #1  
Old 01-12-2019, 07:43 PM
jfisher jfisher is offline
 
Join Date: Jan 2018
Location: C27
Posts: 14
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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140411 Began 1/5/18
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  #2  
Old 01-12-2019, 07:48 PM
ty1295 ty1295 is offline
 
Join Date: Aug 2011
Location: Jeffersonville, IN
Posts: 245
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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, 07:55 PM
rnewcomb7797 rnewcomb7797 is offline
 
Join Date: Mar 2015
Location: el paso, texas
Posts: 7
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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, 08:16 PM
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scard scard is offline
 
Join Date: Jun 2005
Location: Cedar Park, TX
Posts: 2,857
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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, 08:45 PM
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tomkk tomkk is offline
 
Join Date: Apr 2014
Location: Port Orange, Fl
Posts: 815
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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, 08:50 PM
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Steve Melton Steve Melton is offline
 
Join Date: Apr 2011
Location: Cincinnati, OH
Posts: 1,903
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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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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 01-12-2019, 09:18 PM
Stockmanreef Stockmanreef is offline
 
Join Date: Nov 2012
Location: Midland, mi
Posts: 648
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Can you get a very narrow tipped forceps into the slots in the tap and unscrew it out?

https://www.amazon.com/SE-TWSS-C-Pro...ow+tip+forceps

Not sure they are small enough to fit into the tap to do this. Might be worth a try. And for $6 it is worth a try.

just a thought.
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  #8  
Old 01-12-2019, 09:22 PM
xblueh2o xblueh2o is offline
 
Join Date: Apr 2011
Location: SF East Bay
Posts: 775
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Is it not possible to get a tap extractor in there? You can get relatively inexpensive sets of extractors.
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  #9  
Old 01-12-2019, 10:02 PM
jask jask is offline
 
Join Date: Feb 2018
Location: Ramona, CA
Posts: 110
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Tap extractors are not that expensive. Mcmasters. When you tap, always use a quality tap and tapping fluid. When you extract, use tapping fluid and slowly work out and in until it is free. They work well.
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  #10  
Old 01-13-2019, 08:25 AM
BillL BillL is offline
 
Join Date: Sep 2007
Location: Central IL
Posts: 4,727
Default Dissolve it,

Dissolve it. Google and see what acids will do this, it will only take a few minutes with the right fluid. Nitric acid is one, household ALUM is another. It will only dissolve high carbon steels, or at least much faster, and no aluminum at all.

Otherwise, leave it or punch it through.

Tap Magic is a good tapping fluid for aluminum, not the best, but more available. That bar is 6061 alloy and softer and more prone to galling. Tap magic is good for drilling that allow as well.


Edit: The ALUM works, but is slow and requires emersion. Not a good candidate, sorry.
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Last edited by BillL : 01-13-2019 at 08:45 AM.
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