CHill

I was tapping my exhaust for a pyrometer today and the tap broke off flush with the manifold. After a bit of panic, I realized I could use the four flutes cut in the tap to back it out. Just use a small flat head on an angle and a hammer to carefully spin it loose. Luckily I was tapped deep enough to use the threads, and was careful to keep it clean while working. I hope this helps someone so they don't have to take off the turbo.

Nick02Ram

Thats a good idea, just for future reference, they do make a tool for removing them. Its sort of a round fork, where the 4 prongs fit down in the tap flutes and you back it out. Or just use a punch and smack the center of the tap, its hards and brittle enough it usually breaks

JD730

You had 2 things going for you, tapered pipe tap, get looser as you remove it and cast iron, doesn't make a nasty chip that can keep you from removing the tap after it breaks.

There are removal tools, but they only work if the tap is fairly free and not trapped by chips. I've had to use the chisel method before to get them out. A friend of ours claims he can weld some special rod on them with a nut and get them out that way sometimes.

Its not a matter of if, but more of when you break one when using taps.

Colo_River_Ram

Taps are brittle by nature, if embedded in suitable material you can normally shatter one with a punch and big hammer..

If it is a very expensive project check out the video in this process:

http://www.cammann.com/

or there is the better living through chemistry option:

http://www.chemical-supermarket.com/...FSf3iAodVkcLgg

Lil Dog

I don't know if you used it or not, but buy cutting fluid for the tap. Sure keeps the breaking to a minimum to get the proper lubrication in there.

Rott-n-dawg

I have used needle nose pliers to work them out in a pinch. Small, long, and narrow. But the standard ones will work as well just takes longer.

infidel

When they get really stuck and can't be turned out I use a small welding rod with the amps turned way up then hit them for just a second.
They always come out easily after that.

1985cucv

anti sieze works good too! for lube