Help: Broken Tap in Flight Hardware

[KnurledNut]

If nothing else, maybe the tool manufacturers reading this will recognize an empty void in the tool industry, micro tap extraction tools.

 

[dnschmidt]

Amazon.com

Made for this sort of thing.

Interesting. But when has Sandvik, one of the largest carbide manufacturers in the world, become a "small business" brand as Amazon claims it is. NOT THAT'S FUNNY.

 

[RTM]

I'm starting to think this is fake news...

The boy who cried broken tap?
Mandatory updates?

He’s been a member since 2011, with only 368 posts. Guess GJ isn’t his first passion / time sink like so many of us.

 

[Toold_up]

He’s been a member since 2011, with only 368 posts. Guess GJ isn’t his first passion / time sink like so many of us.

I don't know, posting in an online forum asking for help to extract a broken tap in some spaceship part...


Sure, it's possible.

 

[tool_scrounge]

My guess is he mentioned this posting at work and his boss and/or legal department had a stern conversation with him about it.

 

[Bubba Fett]

Well, astronauts called Cartalk for advice one time, so anything is possible.

 

[LopezBart]

Tap removal isn't rocket science. Oh, wait...

This is rocket surgery.

 

[Omnirod]

I realize that I am late to this party; my "Go To" is EDM, Electrical Discharge Machining, for removing broken taps.

I have one of those…I should really knock the dust off of it and hook it up.

 

[cherrybomb]

Use a 6” or so piece of flat steel for a handle. Find 2 small drill bits to fit in the gaps between the flutes. Use vise grips to clamp the bits to the bar with the proper spacing, in the middle with the bits perpendicular to the bar and sticking out enough to reach down into the flutes. Use oil.

Would allen wrenches substituted for the drill bits work like you suggested?

 

[Cc_windsurfer]

Well, I broke a 6-32 tap today. Blind hole below the surface in 6061 Al. My small broken tap extractor is broken as well

 

[rooster59]

Would allen wrenches substituted for the drill bits work like you suggested?

I’d give it a go as long as they fit loose enough. Put them on opposite sides so as you turn counter clockwise they press against the bar.

 

[Beowulf]

Just wanted to let everyone know, we were able to get the tap out. We had to make a custom tool. Basically we took a 256 tap with a collar over it that pinched too tiny tongues of metal in the two flute grooves. Then we epoxy that into place, and probably with only a 16th of the tongue protrusion, we were able to get it into the flutes of the stuck tap and slowly work it

 

[jrevans]

Glad you got it out. Was spitballing this as I read through the thread, was considering a staple from a common desktop stapler, folded in half and inserted between the flutes.

I work on spaceflight ground support equipment, the rules are substantial, but it isn't flight hardware.

 

[Beowulf]

Yeah, the rules are nuts. It makes for some fun challenges, but the paperwork sure slows it down.

 

[KnurledNut]

@Beowulf
Shew, glad you came back and updated us.
This almost became one of those, “legend has it they are still trying to remove that tap to this day” threads.

 

[rust in the eye]

Glad it is sorted out. That part ought to be fine

 

[Beowulf]

I don't know, posting in an online forum asking for help to extract a broken tap in some spaceship part...


Sure, it's possible.

Ha! It’s all good. No mention of program, Customer, mission, or our company name. All good.

 

[willy3486]

FYI for future reference they make a security screwdriver for similar stuff. They are U shaped and here are some examples.

https://www.amazon.com/uxcell-U-Shaped-Magnetic-Screwdriver-Length/dp/B07X8X75TT?tag=atomicindus08-20

 

[Beowulf]

That #4 may have been able to work with some grinding. I found several tools like this but none for the #2 size

 

[Bob K]

Here is an idea how to make this miniscule tool DIY. Two sewing needles fixed side by side with two small rectangular aluminium (titanium) plates. The plates are clamped together with four machine screws. As you assemble the tool, clamp it in a vise so the needles leave an imprint on the inside of the plates (bed themselves in). Those needles are tapered tips and pretty tough steel. Photo showing two sewing needles next to 1.5 mm drill bit.

 

[Beowulf]

Actually, I think that might have worked.

 

[Bubba Fett]

Thanks for the update!

Now if we find that Boeing suddenly has a fix for their doors falling off, we'll know why.

 

[dutchgray]

Actually, I think that might have worked.

I think it might too, though sewing needles are typically very hard so might be a bit brittle, you can make great small scribes out of them.

 

[dnschmidt]

I wonder what half-assed method Boeing would have used. ****, just leave it in there and save a screw.

 

[RTM]

I think it might too, though sewing needles are typically very hard so might be a bit brittle, you can make great small scribes out of them.

That is my fear. I’ve used sewing needles for other things, and broken them every time before achieving my goals. I’d go with drill rod prior to a needle.

 

[mechcsu]

Likely a no go for this situation but I figured I would share this trick I have used before. A broken tap that is wedged into gummy non-ferrous material can be removed with the help of acid. The acid will partially dissolve the steel tap to the point that it can be backed out. The trick is to know someone good with chemistry who can help you select an acid compatible (or nearly compatible) with the base material and its alloying elements but yet able to attack the iron in the steel tap. Once the broken tap is removed remember to neutralize any residual acid.

 

[slowtwitch73]

I wonder what half-assed method Boeing would have used. ****, just leave it in there and save a screw.

Do we know it wasn't Boeing?

 

[Tactile]

Roscosmos? No, they just randomly drill holes and leave them dont they?

 

[dnschmidt]

Roscosmos? No, they just randomly drill holes and leave them dont they?

Hey, rivets and bolts cost money. We're not running a charity here.