Broken tap in mast

[gaucho]

I have a #10 tap that broke (half) inside the mast. I have been unable to remove it. It is high up in the mast, below the second spreaders.

Long story short; I sent the wrong person to do the job.

Now we tried pliers, we tried drilling (titanium drill bit) and achieved ... nothing really. It is just smoothed out, but probably 1/8 of the way to actually drill into it.

Suggestions?

Should I just forget about it, put some silicon there and let it meld together steel and aluminum and just forget it's there?

Im open to whatever experience dictates.

[bletso]

Try an 'unscrew-ums" https://tltools.com

[Tkeeth]

https://www.jbtoolsales.com/walton-t...CABEgJRGfD_BwE

i use a tap extractor

[model 10]

Try and break the tap with a small 3/32"punch. You are going to need to go up to a 1/4" thread in the end.

[Dave_S]

I would want it out, it will rust and contaminate the aluminium. You can try the tools above but I haven't had any luck with small sizes using those types of tools.

I haven't found anything that works other than spark eroding which I'm sure is not going to happen up a mast. I think you are left with trying to punch it through with a hammer and punch or smashing it up the same way.

[UNCIVILIZED]

Originally Posted by Guy

Try and break the tap with a small 3/32"punch. You are going to need to go up to a 1/4" thread in the end.

This sounds about right to me. Though I'd be tempted to freeze it with something super cold, prior to trying to shatter it (or drive it into the mast). And after getting it out of the way, you might get lucky & be able to install a helicoil or other insert into the mast wall, for whatever it is that you're trying to bolt in place there.

The more you tell us, the more we can help.

[Chenega]

Originally Posted by UNCIVILIZED

This sounds about right to me. Though I'd be tempted to freeze it with something super cold, prior to trying to shatter it (or drive it into the mast). And after getting it out of the way, you might get lucky & be able to install a helicoil or other insert into the mast wall, for whatever it is that you're trying to bolt in place there.

The more you tell us, the more we can help.

Yea... this can be a PITA! I agree you should try to fracture the tap with a center punch or small punch. I've seldom had success with tap removers except on my luckiest days.
* be sure to have someone experienced do the tapping next time. I also recommend "Tap Magic" for aluminum.

[a64pilot]

Taps have flutes, these flutes should be accessible with sometimes just needle nose pliers, grab it and unscrew it, or use the tap extractor.
Punch it out and it's sitting on your mast base rusting away.
Easy outs and taps are both extremely hard, drilling either is usually not very successful

[david samuelson]

Get it out, or in, before you go sailing - it could make a big mess of your halyards,

[UNCIVILIZED]

Originally Posted by a64pilot

Taps have flutes, these flutes should be accessible with sometimes just needle nose pliers, grab it and unscrew it, or use the tap extractor.

By this point I typically reach for either my Visegrips, or Water Pump pliers, & the frozen bit, seeing the maniacal glint in my eye, typically rolls over & comes right out. As it knows that otherwise it's in for a serious & painful maiming, prior to being destroyed.
Though I do own needle nose visegrips too

Originally Posted by david samuelson

Get it out, or in, before you go sailing - it could make a big mess of your halyards,

There is this, plus the rather high probability of it terminally maiming a sail.

And if none of the above suggestions works, the Dremel might be an option. Though it'll leave some ugly marks on the mast tube.

[model 10]

Originally Posted by UNCIVILIZED

. The more you tell us, the more we can help.

Well he did say it was a #10, it's broken off down in the hole and he tried pliers. You all have see the flutes in a #10 tap?, Pretty small for or any needle nose pliers.

[LoudMusic]

Originally Posted by Tkeeth

https://www.jbtoolsales.com/walton-t...CABEgJRGfD_BwE

i use a tap extractor

It's a little bit amazing to me that we have invented a tool for removing another broken tool from where it failed.

[DeepFrz]

You may have to use a very small hole saw. One that will just fit over the tap.

[foufou]

You might have success with a pointed grind stone. Centered over the offending item with a fender washer held with a small vise grip pliers. Bend the edge of the washer up so it will sit flat over the tap. Good luck

[Brewgyver]

#10 is tough, but you may be able to use the next size larger drill bit or a pointy dremel stone to expose the flutes. Then you could try snap ring pliers - points into the flutes and turn.