Broken Tap In A Blind Hole? | Best DIY Removal Method

While making a homemade bench vise out of steel I broke a tap in a blind hole. In this video I share my process of trying different methods of removing a broken tap. These methods were suggested on different UA-cam videos and online forums. I hope this video is helpful to anyone who finds themselves in the same predicament.
I am currently in the process of finishing my bench vise - so stay tuned for the homemade bench vise video.
Broken Tap In A Blind Hole? | Best DIY Removal Method
Timecodes
00:00 - Intro
00:19 - Background
02:00 - Using a Punch
03:13 - Diamond Hole Saw
05:20 - Diamond Bur
06:44 - Cut and Weld
09:11 - Outro
Reference UA-cam Video:
• How to drill out a bro...
General Gear List:
Camera - Iphone 14
Camera_2 - GoPro Hero 5
Mic - Rode VideoMicro2
Welder - Titanium Stick 225 (harbor freight
Angle Grinder - 4 1/2" Dewalt
Video Specific Tool List:
Bauer Diamond Grit 3/16" Hole Saw - $7.64 at Harbor Freight
Diamond Grit Bur - $8.68 on Amazon
Pittsburgh Pro Chisel/Punch Pack - $14.99 at Harbor Freight
Check Out My Other Content and Projects:
INSTAGRAM: mooseworks_strength
TIKTOK: moose_works
REDDIT: mooseworks_strength
Contact email: [e-mail]
#mooseworks
#DIY
#metalworking
#welding
#tapremoval
Like, Subscribe & SHARE the video! Also, comment any of your opinions.
Check Out My Other Videos on the UA-cam Channel:
DIY Telescoping Tube Hack
Thor's Hammer from a Rusty Rod Build
Homemade DIY Welding Table
DIY Farmer Carry Handles to Frame Carry
And More...
Thanks for watching!

[@SchysCraftCo.]

Thanks so much. Can't wait to see more updates an projects and many more videos soon moose. Keep up the great craftsmanship and hard work my friend. Fab On. Weld On. Keep Making. God bless.

[@mooseworks]

Thanks for the support man! Let me know if you have something you want me to build!

[@zorinho20]

I have this problem in a motor shaft,where cutting is not an option.
I will try to heat the tap and anneal it.

[@mooseworks]

That is prolly a good option. I think a diamond bit could work also. Just don’t run it at a high speed and burn the diamonds grit off!

[@fontagnepaxton3754]

😃

[@moshebron2105]

Next time use cutting oil when tapping it really helps

[@mooseworks]

I did use some 3 in 1 oil but not cutting specific. If cutting specific oil much better?

[@moshebron2105]

@@mooseworks I use it when tapping and it does well.

[@akbychoice]

@@mooseworksdrill and tap oil will make your life easier. It will make your drills and taps cutter better and last longer.

[@phalanyx3478]

This is why I do not ever buy stuff cheap brand new. If I need cheap stuff I buy premium secondhand tools off ebay, auctions, or flea markets for cheap. Do not ever, ever use cheap threadcutting tools for anything other than chasing/cleaning existing threads. Cheap tools are a liability.
To extract a broken tap with DIY means you order the correct sized and flute count Walton extractor or improvise one. This is the least destructive and first option. If that doesn't work send it to a machine shop and they will either burn it out with an EDM tap burner or drill it out with a bridgeport and a carbide drill. If you tell them to just drill the core of the tap out and leave it, you can get charged less and break the tap out yourself much more easily with the core drilled out.
There are few mistakes more expensive than broken taps. To prevent more broken taps;
Those cheap tap & die sets are liability prone TRASH only fit for chasing threads to clean them up. Look into spiral flute and spiral point taps from industrial suppliers and never look back. Use lubricant. Order a drill index secondhand off ebay to ensure you have the correct tap drill for your thread.
Technique when hand tapping is the most important because you must keep the tap perfectly straight to the hole. A good DIY method is to thread a nut onto your tap and keep it close to your surface so you can eyeball a parallel gap while starting the tap. Use a taper tap when starting hand tapped threads. If you are tapping deep holes such as this you have to back the tap all the way out to blow the chips out.

[@mooseworks]

Thanks for all the info! I can definitely see the benefit of using good quality thread cutting tools. This tap was part of a set I got from tractor supply and it felt pretty squishy under torsion. I wasted a lot of time because it broke. I didn’t think an extractor tool would work for this size, will it?

[@phalanyx3478]

There are sets or individual extractors sold by Walton.