How to Drill out A Broken Tap

A broken tap can bring your work to a standstill, and if you don’t know how to remove it, the situation can become a nightmare. However, drilling out a broken tap is not as difficult as it sounds, but you have to do it with precision. 

If you’re dealing with a broken tap, don’t panic. In this guide, we’ll walk you through the process of how to drill out a broken tap without causing damage to your material.

Can You Drill Out A Broken Tap?

A broken tap can be frustrating and time-consuming, especially when working on an important project. However, the good news is that the right tools and techniques can remove a broken tap. One method is to drill out the broken tap, which involves carefully removing the tap from the material using a specially designed drill bit.

While this process requires some precision and skill, it can be quite effective in removing a broken tap without damaging the surrounding material. So, if you find yourself dealing with a broken tap, don’t give up hope just yet – with the right approach, you can fix the problem and get back to work in no time.

Why Should You Drill out A Broken Tap?

A broken tap is a frustrating obstacle that can significantly hinder your project’s progress. Using other methods, you may lose time, effort, and resources in trying to remove the broken tap. That’s why it’s essential to drill out a broken tap. By drilling it out, you can quickly, efficiently, and safely remove the broken tap. This process allows you to continue your project, preventing further delays or inconveniences.

You don’t have to worry about the broken tap causing any damage or leaving residue behind. Additionally, you can save money by avoiding the need to replace the entire part, which can be expensive. Drilling out a broken tap is a solution that gives you peace of mind and confidence that you can complete your work without any further stress.

How to Drill out A Broken Tap – in 7 Easy Steps

Step 1: Assess the Situation

Before you begin the process of drilling out the broken tap, you have to assess the situation. First, determine whether drilling the tap out without damaging the insert is possible. If a drill bit cannot pass beyond the tap, using this method will only allow you to drill on an angle, which can result in damage. Instead, it’s best to use a different method to remove the tap. However, if you can use the drilling method without causing any damage to your material, you can proceed to the next steps.

Step 2: Choose the Right Drill Bit

Choosing the right drill bit is important to remove the broken tap. For example, if you’re working with a hardened material, you need a carbide or cobalt drill bit. On the other hand, a high-speed steel drill bit is ideal for softer materials. Also, consider the size of the drill bit. Choose one that’s slightly larger than the tap you’re trying to remove.

Step 3: Drill Carefully

Once you have the right drill bit, it’s time to start drilling. Before you begin, mark the center of the tap with a punch for accuracy. Next, drill slowly and carefully. If possible, use a drill press for precision. The depth of the hole should be slightly deeper than the tap to ensure that you remove it fully. If the drill bit becomes hot, take a break, let it cool down, and then continue.

Step 4: Remove the Tap

Once you have drilled into the tap, you can remove it in a few ways. One option is using a tap extractor designed specifically to remove broken taps. Alternatively, you can reduce the size of the hole you drilled and use a screw extractor to remove the tap. This method works best if you can’t grip the tap well with an extractor. Whatever method you choose, be careful not to damage the original threads.

Step 5: Clean and Inspect

Finally, cleaning and inspecting the threads after removing the broken tap is important. Use a wire brush or tap cleaner to remove debris and clean the threads. Next, inspect the threads carefully for any damage. You can always use a thread repair kit to fix the issue if there is damage. Once the threads are cleaned and inspected, you can proceed with your work.

Step 6: Re-Tap

If the threads are in good condition, you can re-tap the hole. First, use a tap drill bit to enlarge and clean the hole. Then use a tap of the same size as before to create new threads. Be sure to apply plenty of cutting fluid when tapping the hole for lubrication and easier cutting.

Step 7: Use the Right Fastener

Finally, when it comes time to use a fastener in the tapped hole, make sure you select the right one for your material and application. For example, if you’re using soft materials like aluminum or brass, you might want to choose a self-tapping screw instead of a machine screw. Also, be sure to use the proper size and length for your application.

By following these steps for drilling out a broken tap, you can remove it without causing any damage to your material or threads. You can safely and successfully complete this project with the right tools and techniques. Just remember to take your time and be careful with each step to ensure a successful outcome.

5 Considerations Things When You Need to Drill out A Broken Tap

1. The Type of Material the Tap is Made From 

The first consideration when you need to drill out a broken tap is the type of material the tap is made from. Taps can be made from a variety of materials, including brass, steel, and iron. Each type of material will require a different drill bit to drill through.

2. The Size of the Tap 

Another consideration is the size of the tap. Taps come in a variety of sizes, from small taps that are used for sinks to large taps that are used for bathtubs. The size of the tap will determine the size of the drill bit that you need to use.

3. The Type of Drill Bit 

Once you know the material the tap is made from and the size of the tap, you can determine what type of drill bit you need to use. Various drill bits are available, each designed for drilling through different materials and sizes.

4. The Depth of the Hole 

Another consideration is the depth of the hole that you need to drill. Taps can be recessed into the sink or countertop or protrude out from it. The depth of the hole will determine how long of a drill bit you need to use.

5. The Direction of the Hole 

Finally, you need to consider the direction of the hole that you need to drill. Taps can be drilled straight down into the sink or countertop, or they can be drilled at an angle. The direction of the hole will determine which type of drill bit you need to use.

With these five considerations in mind, you’ll be able to properly drill out a broken tap and replace it with a new one. 

It’s always important to understand the type of material, size, type of drill bit, depth, and direction of the hole before starting any project involving drilling. Taking your time and doing the job right will ensure that you get the best results.

Benefits of Drill out A Broken Tap

Breaking a tap during a machining operation can be a frustrating experience, but there is a solution that can save you time and money without the need to replace the entire workpiece. The process of drilling out a broken tap is not only effective but also beneficial in many ways. 

Firstly, the drill out method is cost-effective and saves you money compared to replacing an entire workpiece. Secondly, it can save you time, as the process is often quick and efficient and allows for the immediate continuation of your machining project. 

Lastly, the drill-out method is a reliable and accurate solution, ensuring that your workpiece remains intact and is of high quality. The benefits of drilling out a broken tap are undeniable when it comes to maintaining productivity and minimizing downtime.

Some Common Mistakes People Make When Trying to Drill out A Broken Tap

When it comes to drilling out a broken tap, even experienced handymen and DIY enthusiasts can struggle. One of the most common mistakes people make is using the wrong type of drill bit. A regular drill bit simply won’t cut it – you need a carbide or diamond drill bit designed to cut through tough materials like hardened steel. 

Another mistake is using too much force or drilling too quickly, which can cause the drill bit to overheat and become dull. It’s important to take your time and let the drill bit cool down periodically to avoid this. Lastly, forgetting to lubricate the area around the tap can cause the bit to seize up, making it difficult or even impossible to continue drilling.

You can successfully remove a broken tap and get back to your project by avoiding these common mistakes and using the right tools and techniques.

Conclusion

Removing a broken tap can be stressful, but with the right tools and knowledge, you can do it without causing damage to your material. Remember to assess the situation before drilling, choose the right drill bit, drill carefully, remove the tap without damaging the threads, and clean and inspect your work. 

This process sounds simple, but it requires patience and precision to get it right. By following these steps, you can safely and effectively remove a broken tap and get your project back on track. Thanks for reading our post about how to drill out a broken tap.