Broke a 6-48 bottoming tap off in the hole and can’t seem to get it out. Have tried the tap removal tool to no avail. Does anyone know of a fool proof way to get a broken bottoming tap out of a hole?
If it is a high carbon steel tap, just take a punch and hit the tap smartly at an angle, then hit the tap from the other side, the tap should fracture and come out in pieces. For high speed steel, you can use a very small diamond coated burr and with your Foredom/Dremel tool cut up the tap. Be aware this takes some time. You can also grind out a SMALL area where the tap is imbedded in the metal and jockey the tap out. Last of all you can wallow out the hole SLIGHTLY; just enough to get the tap out then re-drill and re-tap to a larger hole. Hope this helps.
