How to drill out a broken tap | drill out a broken screw extractor

In this video I drill out a broken tap using a JCB diamondtech holesaw. Drilling out a broken tap or drilling out a broken screw extractor is often very difficult and most people would get the broken tap or broken screw extractor spark eroded. There are not many drill bits that will drill HSS taps or screw extractors as they are harder than most drill bits, but the JCB Diamondtech holesaws slowly remove the hard steel. The Diamond Tech holesaw cost £17.50 from Toolstation (I’m not on commission) www.toolstatio...
Some more videos that might be of interest are-
How to remove a broken bolt which is deep in a hole - • How to remove a broken...
How to make the bolt drill guide can be seen here- • How to drill through t...
How to remove a rounded Allen head bolt- • How to remove rounded ...
How to remove a stripped screw- • How to remove stripped...
How to remove a broken bolt- • How to remove a broken...
How to remove a rounded nut or bolt- • How to remove a rounde...
Screw extractors | Easyouts - • Screw extractor | easy...
Removing a broken bolt using a welder- • Removing a broken bolt...
Remove a broken bolt using a left handed drill bit- • Remove a broken bolt u...

[@nopleaseno2515]

God bless you, your wife, ex wife, children, siblings, mom, dad, grandparents, dog, cat, pets, house, garage!!!! So needed this video right now!!

[@ultimatehandyman]

Thanks for the comment 👍

[@ashleyburton8605]

I can't believe you did this as a demonstration! You must love spending time in the garage. This situation is one of the worst

[@ultimatehandyman]

The main reason why I did this is because a few people commented on a previous video where I drilled out some broken bolts, normally with comments like "that's easy- try drilling out a broken tap", so I did. Now I'm waiting for the "it's easy on a bench- try doing that when you are in space - wearing a space suit" type of comments 😉 Thanks for the comment

[@Naasbc355]

@@ultimatehandyman this is easy. Just wait til you have to do it hanging upside down from the monkey bars while fighting off a pack of angry wolves and on fire. Ya! That'll make a man outta you!

[@ThePjstokes]

I have to do this on an exhaust stud that broke in my mr2 and broke an extractor trying to remove the broken stud lol deff worth the watch I have to go pick up some of those diamond bits

[@druegeme]

@@ThePjstokes hey I have the same thing in my Suzuki m50 bike exhaust bolt right now! any tips?

[@Alistair]

@@druegeme make sure to stop for a tea every now and then

[@Yawwee]

I really like that idea to have a hole in the center of a bolt to guide your drill bit in nice and straight and not ruin any threads when drilling in the broken bolt !!!! Ingenious !!!!

[@ultimatehandyman]

I’m glad you found the video useful Thanks for the comment 👍

[@icespeckledhens]

Thanks for demonstrating a procedure which most of us try to avoid but sometimes you have to do it. As you showed, it's very time consuming and patience, care and persistence is essential. Thanks

[@rickguyevans]

What a great video...being a much more experienced millwright at a food plant in Canada, I am constantly being asked to remove broken bolts/taps/extractors from stainless equipment! The younger ones just don't have the patience or experience in removing their mistakes. Once worked with an expert in a steel mill who was able to remove any broken object in a threaded hole. Cheers and thanks for sharing. Rick from Hamilton, Ontario:)

[@ultimatehandyman]

Thanks Rick, we have a lot of stainless equipment at the place where I work and it definitely requires patience ;-) Thanks for the comment 👍

[@1pcfred]

Some stainless is a nightmare to tap. I go for less than 50% thread. Sometimes a lot less. Even the shadow of a thread can hold in stainless. I look in the hole and can barely see any thread. A fastener will still grip tight though.

[@nameredacted1242]

Thank you for your work, Rick!

[@hpt08]

This has to be an Ultimate Handyman platinum edition video. Pure gold at any rate!

[@ultimatehandyman]

Thanks for the comment 👍

[@peterfitzpatrick7032]

I love how the tap refused to play ball & break... & when it did, it broke in a place I have never seen a tap break in my 30 years experience as a machinist / repair guy... 🙄😂 If you could rig it so you were drilling vertically & had a continuous flow of cooling water, you would have speeded the job up... but thats not always possible. Thank you for going through the whole effort to show the process involved... Regarding tapping the hole or using an extractor... in situations like this particularly, I use a NEW tap, preferably a Presto spiral-point machine tap and use a good quality cutting oil like Rocol or similar, backing out, cleaning the swarf out & going in again ... patience is the name of the game. I think its even more critical to use top quality extractors as they are almost glass-hard & very brittle. Presto brand was my favourite...and yet I have managed to snap even those... 😖 Carbide tipped masonry bits can be used in a pinch but need grinding to put a positive cutting rake angle on the tip... There is a great sense of achievement & satisfaction in successfully doing a job like this, particularly if the part is expensive to replace or maybe even irreplaceable.... You've got a sub & a like from me based on this vid alone... good job mate 😉 From the Emerald Isle 😎👍☘🍺 www.rocol.com/products/rtd-chlorine-free-liquid www.presto-tools.co.uk/ProductGrp/metric-coarse-spiral-point-taps-iso-529 www.presto-tools.co.uk/Products/screw-extractor-sets/096001-6

[@ultimatehandyman]

Thanks for the detailed comment 👍

[@lincolnengland3596]

Great video yet again....As a compulsive fixaholic I love to see stuff coming back from the grave.....I've spent a tenner to fix stuff worth a fiver just because I can! Keep up the good work!

[@ultimatehandyman]

Fixing things is always worthwhile, even if it's just for the practice of doing it. When I was a kid I remember replacing the element in an electric kettle for a elderly friend of the family. I bet you can't even buy a kettle element these days as electric kettles are so cheap! Thanks for the comment

[@frankconley7630]

Would you drill out a brake caliper bleeder screw or buy a new caliper?

[@PacoOtis]

From here in the States we say thanks for an excellent video and we definitely owe you a brew!

[@ultimatehandyman]

Ironically I'm drinking a brew right now 😂 Thanks for the comment 👍

[@kseselja]

When you were drilling you used a right hand drill bit. Would a left hand drill bit been better? Could it possibly help dislodge the broken bolt?

[@ultimatehandyman]

@@kseselja No, these diamond bits to not bite at all, they just grind away at the material. Thanks for the comment

[@ewzm]

I started out with the diamond hole saw bit method you demonstated here but became discouraged with the slow going. I picked up a Milwaukee carbide multimaterial bit (4 or 5 inches long and looks like a masonry bit) at a home improvement store for about $8.00 US. With this, the broken extractor was completely drilled out within 10 minutes. I still needed to tap new threads as you demonstrate in the video. Thank you.

[@ultimatehandyman]

Great to hear!

[@player1tv]

Just snapped a 8mm 316 stainless bolt off, drilled it out to 6mm, stuck the easy out in and it snapped off flush. I watched 4 videos on removal options, purchased, drill bits, dremmel bits and spade type tile drills. They all broke. The only thing that worked was your tile drill bit. It seemed like it wasn't working after the initial sharpness wore off, so instead of going slow i just hammered it for 10 seconds at time, refreshing cutting fluid and it worked. Over all, 6 hrs of trying and failing, 30 mins of your method and success!! Thank you, one can stop swearing now.

[@ultimatehandyman]

Well done for being so persistent and not giving up 👏 👍

[@EspatiallyGood]

Thought I would update on here as a way of saying thanks! This method totally worked for me. My situation was slightly different, because I had to do it in situ. Also the bolt I snapped off was smaller diameter (M6) and therefore the extractor was smaller too. I ended up going on ebay and purchased a pack of x10 4mm diamond hole saws, and because they are so small I ended up getting through all ten of them before getting through the extractor. But the pack of 10 was only about £10, so well worth it. I could then drill the rest of the bolt out and re-tap the hole. Great advice on taking your time with this job, it pays off!

[@ultimatehandyman]

Brilliant! Well done for having the patience and perseverance to complete the job 🙏

[@dustyrhodes2717]

Would a pack of 5mm hole bits be better? Was this a bolt that broke or a tap? I have the same issue.

[@masonrichardson6581]

This has saved me from hauling my block to shop. Thanks!

[@ultimatehandyman]

I'm glad the video helped Thanks for the comment 👍

[@rodgerq]

Love the idea of a bolt as a centre guide, so simple and effective! Great video.

[@ultimatehandyman]

Thanks for the comment ;-)

[@ultimatehandyman]

This video took a massive amount of time to film and edit, which is why there was no upload last Sunday (I’m also busy working and busy doing other things). Please like, comment and share the video (if you can), as it really helps me out. I hope everyone has a great Sunday 😉

[@bluenapalm123]

Thumbed up. I got a good sense of the effort expended in the work, let alone the post video work :)

[@TheTC2]

I have a cast iron manifold on my old MGA with 3 rusted in bolts that I want to renew. I have tried heat and penetrating oil and a pair of nuts locked together but have not moved them at all - advice would be appreciated. You have provided some interesting ideas, I am impressed, thank you. Tony Clarke.

[@ultimatehandyman]

Studs that are rusted in can be a real pain. You have to be really careful with manifold bolts as they easily shear. I'd keep applying the penetrant, but also shock the studs by hitting the end of them with a punch and hammer. The shock can sometimes work wonders. If that does not loosen them, you could try putting two nuts on the stud, tighten them together and then try tightening the studs slightly, before trying to undo them. Best of luck with it ;-)

[@jodysanders1111]

Good job altogether. These tasks are very challenging. Some great tips I never thought thought of before. Thank you,again.

[@michaelsummers8477]

link to the guide?

[@ronwhite9117]

If your still around, I first watched video 4/8/2022, you've helped my dilema tremendously!!!! THANK YOU! I have subscribed.

[@ultimatehandyman]

Awesome, thank you!

[@sandrarichardson2713]

I felt like I was watching a suspense movie. That was amazing that you just rolled with the flow and ended up victorious. What a great set of methods you resorted to with each problem and the patience. And I will say also, like the others, walking away from really stressful, critical problems really saves the day oftentimes. Take that break. Jesus bless.

[@ultimatehandyman]

Wow, thank you!

[@danmoreton1788]

Thanks for another quality video. Your step wise approach to a difficult task is a lesson for all of us!

[@ultimatehandyman]

Thanks for the comment 😉

[@jgoguen6984]

Excellent video!! The mini tile hole saw saved me a trip to the machine shop and worked like a charm! Thanks Again!!

[@ultimatehandyman]

I'm glad the video helped Thanks for the comment 👍

[@PaulHigginbothamSr]

Mr ultimate probably the very best thing you can add to you toolkit after the centering bolt is a set of left had threaded drills. I can sharpen my own drills by hand because I have done it so long. If you do sharpen your own make the bite very aggressive. It is many times faster than your method but it is very nice to have your method to fall back to.

[@jw200]

Thanks for the tip with diamond drill bit Didn't know that these exist. I bought a 6mm and will try to drill out the broken drill bit from my car flywheel. There is a hole to block the crankshaft from rotating and the drill broke off when i forgot to remove it and i turned the starter. Now im changing the clutch and i want to remove the stuck piece in it. It's amazing actually that some stone called diamond is harder than any hardest metal and it eats it like butter

[@ultimatehandyman]

Absolutely, it is amazing how hard diamond is! Thanks for the comment 👍

[@GeeTheBuilder]

As always, great video 👏👍 In particular, your advice to “take a break” and “not to let it wind you up” is superb advice for someone who is learning about any jobs really. Finally, I’d never even thought to use a “diamond tile hole saw” to drill out metal. I know I know, some will say it’s “obvious” - but it wasn’t to me. So thanks 🙏

[@ultimatehandyman]

You are welcome ;-) Thanks for the comment

[@clauspetersen840]

@@ultimatehandyman The “diamond tile hole saw” was new to me as well. Probably expensive, but a nice option if you can afford it (i have no idea what it costs, but its probably expensive). Anyways its on the list for x-mas presssies my loving family can bestove me with, but they will probably just give me a gift wrapped pair of second hand socks as usual. :)

[@randywl8925]

​@@clauspetersen840 Actually fairly cheap. That man has patience.

[@austingode]

Really good tutorial and sound advice ...... I screwed my shoulder and arm up by not taking a break and getting stressed out drilling through glass ....... stress is a killer

[@ultimatehandyman]

Thanks for the comment 👍

Thank you so much for this idea. Great to know I'm not the only one going through this hell. Hope it works!!🤞 I'll update hoe it goes.

[@ultimatehandyman]

Best of luck with it 👍

[@jesuiscequejesuis2267]

The thing to remember with taps is: don't faucet.

[@ultimatehandyman]

LOL Thanks for the comment

[@davidwrighton3914]

fawcett

[@chris_ackroyd]

Go and stand in a corner and think what you said!😁🤣

[@pavelsustr2145]

Kudos to your video and thank you for posting! I broke a bolt extractor, and your removal method was the only one that had worked. To make matters worse, the area was hard to access, so I had to get a right angle drill attachment and a quick release diamond hole saw. Turned out to be a two day job, but in the end I succeeded. Thank you!

[@ultimatehandyman]

Bolts always break in difficult to reach areas when I'm on site, they can be a real pain in the backside. I do get a lot of comments saying "it's easy when it's on a bench", I don't think some people realise that it's 100 times easier to film when it's on a bench! I'm really glad that you managed to get the broken extractor out- well done ;-) Thanks for the comment 👍

[@EspatiallyGood]

Oh man im having a bad time right now. I snapped a bolt on an exhaust manifold and then snapped off an extractor in the bolt. So I am in a simmilar situation. Worse thing is that I can't take the manifold off, without a garage taking the body off the vehicle.. so it's got to be done in situ. I have some solid carbide bits coming, and some diamond hole cutters coming as well. I am worried that I might snap a carbide bit off in the hole and then things will be even worse... so I will probably take the extra time to do it this way. It's good to know im not the only one, and if i take the time I will eventually get it out again. Cheers.

[@hugorujeles87]

Persistence and patience and a'lil experienced know-how are INVALUABLE skills that help you out of the inevitable holes we all find ourselves in from time to time when life decides to kick you in the Jimmy's 😳💥🦵excellent 👌 content bro this is definitely one that goes into the life toolbox 🧰 keep'em coming 😎👍💰

[@luketuttiett]

That’s an excellent point about not letting jobs get on top of you

[@ultimatehandyman]

Thanks Luke ;-)

[@cybair9341]

I ran out of patience just watching the drilling process. So I paused the video; got myself a "cup o' tea", and resumed the video. Thanks for the education.

[@kougerat5388]

@@cybair9341 Nice one 😂

[@ryanlewis4123]

I just broke off and easy out inside of a really small bolt in my dirt bike..... so depressed right now

[@hpt08]

Unfortunately, it's usually how you get into this spot in the first place. Definitely great advice.

[@fredfarnackle5455]

Excellent video! Great tip about the drilled out bolt for use as a drill guide.👍

[@ultimatehandyman]

Thanks 👍

[@antonio011851]

I second the comment on marketing the drill guides.....I would be your first customer!

[@ultimatehandyman]

Thanks Tony, I messaged my mate today, hopefully he will sort some soon. Thanks for the comment

[@iantunnicliffe4509]

😮you did really well doing that it can be really stressful 😢

[@ultimatehandyman]

Probably why I have had two heart attacks 😂

[@rangerbravo]

You've the patience of a saint

[@ultimatehandyman]

Thanks for the comment 😉

[@MIKET5609]

I previously viewed your video that went into more detail regarding using guide bolts... it's a great concept! Does any of you KZbinrs know if someone is selling guide bolt sets??? I'm really not set up to make precisely centered holes in the center of "allen head" cap screws, and most in my experience tend to be a bit harder than the typical bolts laying about in my shop or those at the big box stores. Thanks for your efforts to produce your vids... gives us a LOT of useful advice!

[@SniffBackBetter]

Brave and selfless man subjecting yourself to this just to show us all what to do! Would another option be to carefully build the height of it up with a welder and then weld a nut to it?

[@ultimatehandyman]

Yes, you can try the welder, but normally if a tap has broken it will normally beat my welding skills ;-) Thanks for the comment

[@karlk6860]

Good information and I did not know about those little diamond tip hole saws I will be getting a set of those for sure! Any time you have unlike metals together like this I am not shy using anti_seize compound on the threaded bolt going into the aluminum its a practice that can save you a whole lot of time later on! Thanks for sharing its very good information!

[@ultimatehandyman]

Thanks for the comment 👍

[@mikef3300]

Thank you so much for uploading this video. I broke an ez out off in a transmission pan bolt and was able to remove it using your method. Your knowledge is greatly appreciated

[@ultimatehandyman]

You are welcome Thanks for the comment 👍

[@sharifsircar]

Taking a break is a very good tip

[@ultimatehandyman]

Thanks for the comment 👍

[@dannypalmer7701]

Gotta have patience and think it out and dont rush.Tell the customer aheade of time that this can happen !

[@ultimatehandyman]

👍

[@davidm3210]

That was pretty. When going up a size, is it unnecessary to bore the hole smooth first, or can you just tap over the remnants of the original threads? I wonder what is the best way to minimize the jump in bolt diameter. I reckon there would be implications for hardened steel suspension components. Thanks for sharing!

[@ultimatehandyman]

It's important that the hole is the correct size for tapping, so it would need drilling with the correct size drill bit first. There is a metric guide on this page- www.ultimatehandyman.co.uk/how-to/metalworking/tap-and-die 👍

[@phonotd]

Excellent video, as usual, very informative and to the point.

[@ultimatehandyman]

Thanks for the comment

[@chass5438]

15:00: Snap ! "Somebody threw a spanner, they threw it in a hole".

[@ultimatehandyman]

😂

[@uktony1525]

The sound of crying when you broke the tap was me. Very, very impressed as I have always considered a broken tap deep within a stud hole as being an unrecoverable situation. A HUGE thumbs up.

[@ultimatehandyman]

Thanks Tony, once a tap is bottomed in a hole and snapped off, it is never going to be easy to sort it out. I'm delighted that you found the video useful 😉 Thanks for the comment

[@theronrose955]

I have used a dremel bit that was tipped with diamond. Used it to hollow out a broken tap, then drilled it shattered into peices.

[@ultimatehandyman]

Thanks for the comment 👍

[@dauntevivone3578]

This video got on top of me and I still have a broken screw with a broken EXTRACTOR in the aluminum head of my car motor.

[@ultimatehandyman]

😱

[@alanweir37]

Brilliant video, I would have give up. That must have taken you forever to do. Well done.

[@ultimatehandyman]

Thanks for the comment

[@Artur1959]

That cup of tea before the job gets on top of you makes the difference between smashing the whole piece, and continuing with the fine, slow and relentless spirit. thanks

[@ultimatehandyman]

Absolutely! Thanks for the comment

[@MrBscott78]

YES! This worked for me. In the past I’ve used diamond hole saws on enameled cast iron, so I’m not sure why I didn’t try it immediately. Instead I tried the Dremel route, as recommended on many videos and discussion boards. The thing is, Dremel grinding stones wear away pretty quickly, and they aren’t all that cheap either. A 2-pack of conical burrs is $15 CAD, and I quickly went through about 4 of them grinding down maybe 1/3 of the broken EZ out. The diamond hole saw was $25, but it ate through the remainder in under 5 minutes! That’s with me being patient and frequently dipping in water as he does here. After that it was simple enough to drill out the sides of the hole, re-tap, and Bob’s your uncle. It’s also worth pointing out that multiple mechanics and machinists I spoke to didn’t offer any solutions to the problem. Kudos, man, thanks for the tip!

[@jameshanoomansing1442]

very skilled work...thanks for sharing

[@ultimatehandyman]

You are welcome Thanks for the comment

[@CR-xl7zu]

Good tip on the diamond hole saws. I didn't know they existed. Any reason they can't be run in reverse? Seems like the vibration might walk the stuck piece out, just like a left-handed drill bit sometimes does. As long as the diamond pieces don't have a directional property, it seems like that would be OK.

[@ultimatehandyman]

Yes, you can use them in either direction, but they tend to file away the metal, so it is unlikely that they will bite and remove the damaged bolt, but I guess it makes sense to drill in reverse- just in case it bites Thanks for the comment 👍

[@dallasshell6455]

You might try running your diamond drill counterclockwise as you drill. I have used left hand spiral carbide drills to drill the pilot hole in bolts to accept an easy out. Many times the bolt will come out while drilling the pilot due the constant unscrewing forces while drilling.

[@ultimatehandyman]

I'm afraid that diamond coated bits do not bite, like a standard drill bit- they just grind away the material. Thanks for the comment 👍

[@spelunkerd]

I've read about a device called a tap extractor, which has three arms that go down the flutes of the tap. I saw one guy on youtube carefully back out a broken tap with that. Any thoughts?

[@ultimatehandyman]

I have seen those, but I can't see them working in most cases. If a tap breaks because it has bottomed out in a hole, I really can't see one of those extractors working to be honest. Thanks for the comment 👍

[@allthegearnoidea6752]

It’s a really good tip that taking a break helps get the job done. I bet you could have Jerry rigged some cooling once you had removed the guide bolt. My background is electronics and I am planning to build a spark erosion tool one day.

[@ultimatehandyman]

Absolutely, I've seen people get wound up over a piece of metal in the past and it does you no favours! The spark erosion machine sounds ace, I'd love to see that when you have made it. Thanks for the comment ;-)

[@1pcfred]

I'm getting wound up just watching this video. When I worked in a tool and die shop if we broke a tap we'd take an old reamer and grind a sharp point onto it. Then we'd put that down the hole with said broken tap in it and batter it with the punch made out of the reamer and a hammer. Taps are glass hard so they shatter when struck. That method isn't 1, 2, 3 either but it beats what I'm seeing here. Done right you should be able to bust the tap up into crumbs which you can pick out as you go along. Pro Tip: Try to avoid breaking taps. Because removing them is tedious and can potentially wind you up!

[@tahirotahir]

I broke a Cobalt drill bit tip inside the glow plug hole of an engine. So far made the job worst by trying using multiple drill bits because tips keep sliding off of each other (tip of stuck and broken bit piece and tip of my extracting drill bits). Question is, based on your experience will this be able to drill out such metal? Please do reply as I am in serious need of any jelp from anywhere. Please...

[@osvaldocristo]

Thank you. It looks it did not occurs *only* with me! Great to feel not alone! :-0 BTW I use counterclockwise bit rotation and left twisted bit in the hope the screw goes outwards alone... it worked a couple of times.

[@ultimatehandyman]

Thanks for the comment 😉

[@trivialinsignific]

right on dude !

[@rowdy97914]

Thank you so much I’m fighting a broken easy out and bolt flush at the front of my crank this idea is the only one that seems to be working

[@ultimatehandyman]

You are welcome Thanks for the comment 👍

[@paulmorrey733]

Great video Very useful Thanks

[@ultimatehandyman]

You are welcome Thanks for the comment 😉

[@kaylecarlile6708]

Are you using water or oil to cool the bit? What’s the benefit of one over the other? I’ve always just used WD40 in between drilling.

[@ultimatehandyman]

When I was at college, my tutor said that water was the best coolant, but anything is better than nothing 😉

[@Aksankhan]

Always great work Thanks for sharing

[@ultimatehandyman]

Thanks for the comment

[@johniac7078]

Does the Mrs. know you are using her bread pan to cool your drill bit? LOL. Very good info.

[@ultimatehandyman]

She does not know yet LOL Thanks for the comment 😉

[@MrIhatespamiam]

Thanks for posting this. Worked like a charm and saved tons of time from teardown.

[@ultimatehandyman]

Glad it helped 👍

[@davidfusco6600]

You offer good solid advice! I’m a machinist in New York, I work often with aluminum 3/4 inch thick plate, usually sizes range from 19.00 x20.00 to as large as 36.00x30.00, either 6061, or jig plate. Saving a plate this size is a priority. We machine these plates on a VF6 Haas machining center. Occasionally, taps break. Since these are always in house items, I have a lot of leeway on how I extract the broken tap. My preferred method is to use a fractional size carbide end mill. Say for a 1/4-20 tap, I’ll use a 1/4 inch endmill. Usually 900-1100 spindle speed, sometimes flood coolant, other times I’ll use Moly-D cutting oil from a can. I crank down the spindle in the manual mode in tenths (.0001) with some luck, one endmill will survive doing the job, other times I’ll go through 2-3. Once the hole is cleared, I’ll re drill and tap for a 1/4-20 Heli-Coil insert.

[@kendrom]

Pretty much the same method I use as well. Although, you could use a 5mm carbide endmill, and not have to use a heli-coil. A 3/16ths might do it as well?

[@frankconley7630]

Wow. Thanks for sharing. Do you use a normal electric hand drill.

[@richardsalinetrojr1957]

If your working with aluminum you can always dissolve the tap by soaking piece of aluminum for a few hrs or overnight in a heated solution of Battery Acid and Alum (potassium aluminum sulfate). method works great for aluminum but does take awhile. won't harm the aluminum in anyway whatsoever but it may discolor the aluminum but the discoloration rubs right out with a good aluminum polish or can just hit it with a piece of fine sandpaper. done this method many times breaking off small taps like 1.5mm and 2mm I use for aluminum parts for R/C vehicle parts and it works awesome. works well enough that I actually have a glass jar filled with the solution in garage just for those rainy days that ill need it. lol

[@nameredacted1242]

AWESOME INFO, THANKS FOR THE SPEEDS, LUBE, ENDMILL INSTRUCTIONS!!!

[@johnguilfoyle3073]

If you're breaking taps frequently, why not buy a metal disintegration machine and do this job in a few minutes?

[@winstonbarnett2051]

Slow that drill down 🙄

[@johngardiner6800]

Can you explain why you broke the first tap and drilled through it

[@ultimatehandyman]

People often break taps/screw extractors/drill bits, which are all made from a similar tough steel, which cannot be drilled out using regular drill bits. This video shows that it is possible to drill out hard steels, without using a solid carbide bit 👍

[@georgew.8293]

I've just stumbled upon this video. I've had a spark plug break off in the head of my son's 1995 Tacoma. I tried to use an extrator to remove the threads and that broke off. I now need to remove the extrator and I'd like to remove it without removing the head. I believe this will work, but I have nothing to use as a guide for the bit. Can anyone give me any ideas?

[@joelblauvelt5062]

Nicely done. Thank you!

[@ultimatehandyman]

You are welcome Thanks for the comment

[@ambydaly5713]

If you break a hardened tap in a hole, find a machine shop with a spark eroder. This is the professional method to do this job and the simple way. This will also preserve the thread.

[@ultimatehandyman]

👍

[@jimbos3421]

Left handed drill bits are also a good trick to use, they will usually spin the remains out when they grab.

[@ultimatehandyman]

🤔

[@dogphlap6749]

Thank you.

[@ultimatehandyman]

You are welcome Thanks for the comment 👍

[@stuarthelliwell6784]

Sorry but I just can't help myself commenting on this clip anyone who has managed to break a tap the size of the one he used as a demonstration should not be allowed within 50 ft of a workshop "he had to use a sodding lump hammer!!!" as an apprentice every tap I broke usually 2mm downward I received a hefty clip to the back of my head,,,,

[@David-hm9ic]

There are many ways to remove broken bolts and taps and I've used many of them. THANK YOU for teaching me another way!

[@ultimatehandyman]

You are welcome Thanks for the comment 👍

[@alext8828]

Is that a tubular drill? Can't you fill it with water instead of constantly stopping to dip it into the water, or turn the pan so the hole faces up and fill it with water?

[@ultimatehandyman]

Yes, it’s a tube, but not sealed at the end 👍

[@alext8828]

@@ultimatehandyman Duly noted. Thank you.

[@bobber55]

I believe I would use water in a spray or squirt bottle rather than dipping that diamond bit into the water tray that would also help flush out any steel particles.

[@ultimatehandyman]

You could do that, or even set up a water jet pointing at the hole. Thanks for the comment

[@mozzer999]

I recall years ago being told the only way of doing this was via 'spark erosion' at a huge cost. This is a revelation. Thanks

[@ultimatehandyman]

Yes, I know a lot of people that believe that 😉 Thanks for the comment 👍

[@johnrichy2k6]

I'm curious to see how the drill itself held up to this, as well as how many battery changes you went through? For a task like this I'd not dream of using my Makita 18v drill even with the 5ah batteries I'd just imagine it being a total pain, I'd opt to go for the 110/240 SDS and a chuck adaptor? Was there a reason you chose to use the drill that you did? I'm just a humble electrician so not massively clued up on the engineering side of things like this so genuinely interested to see your reasoning, cheers!

[@ultimatehandyman]

To be honest I would have used the 18v AEG drill that I have (it was sent by a PR company a while back), but I realised that the batteries were flat, so I used the Dewalt. If I remember rightly I started off with a partly charged 5AH battery, but had to swap to a 4AH battery. I'm not keen on SDS chuck adaptors as they can wobble, which would not be much of a problem with the diamond hole saw, but it would not have been good for the final drilling with the tapping size drill. Perhaps a mains power drill would have done the job faster, as they normally rotate faster, but for convenience I prefer to use a cordless drill. Thanks for the comment

[@fujiar0018]

Hi.Thanks for a great video!Can U give some info about the diamond core drill please?(i.e. make and supplier.Love your topics and am a new subscriber!

[@55boomhower]

I used this method as a last ditch effort and it worked!!! Broken bolt on a boat motor wouldn’t break loose after welding a nut on, heat, broke an extractor off in it, but this got it out. Took 45 minutes or so using his exact method! THANK YOU FOR POSTING THIS!!!

[@ultimatehandyman]

Nice work! Thanks for the comment 👍

[@Flexaret]

I've worked with a few very good fitters in my time, old school, hands on but you're on a different level. I don't know who your employer is or how much they pay you but it isn't enough. I think the important thing to learn from this video is "don't break the tap/screw extractor"

[@ultimatehandyman]

Thanks, I've worked with some brilliant fitters over the last few years and I've learnt a lot from them, I still work with one of them now (he was 65 on Friday). Thanks for the comment ;-)

[@GeminiSeven43]

One thing that has made removing broken bolts/screws easier for me is the use Left-Hand drills when drilling out the center of the broken bolt because sometimes they will snag and turn the screw out for you saving time and effort. This would be after getting the center drilled if you were to use the drill guide that he made/uses. Great video and I will be looking for these JCB drills. Thanks so much!!!!!

[@ultimatehandyman]

Absolutely, left handed drill bits are great ;-) Thanks for the comment 👍

[@michaelstreets7816]

Excellent!

[@ultimatehandyman]

Thanks for the comment

[@cammyers2910]

I used a Dremel and several diamond bits to get the EZ out ground away and then I was able to get the bolt out of my transmission

[@ultimatehandyman]

Thanks for the comment 👍

[@ashawhite1041]

Someone please help me understand. Is it shaving it down or actually drilling it out?

[@ultimatehandyman]

Diamond coated drill bits are slowly grinding away, as they are highly abrasive. Thanks for the comment 👍

[@ashawhite1041]

@@ultimatehandyman Thank you for the response. This is exactly what I need

[@clauspetersen840]

Very good. If you break a tap its a disaster, usually. I am happy to learn that there are still options that does not require a repair shop. I liked the emphasis on self control. When i was a teen tinkering with stuff my dad always tried to teach me to take a 15-30 minute break when i felt a rage and need to smash things up with a hammer. It cost me a fortune in broken stuff before i finally learned the wisdom of those words. :) 5 out of 5 for this video!

[@ultimatehandyman]

I've been told that I have a lot of patience, but I do swear a lot when doing jobs like this- especially when I was on site! A guy that I worked with on site had even more patience than me (Vinny Davies), he had the patience of a saint for sure! Thanks for all of your comments 👍

[@Master-ls2op]

i use diamond burs to drill them out.

[@ultimatehandyman]

👍

[@c50rider87]

good job thank you sir

[@ultimatehandyman]

Thanks for the comment 👍🏼

[@davidpond6883]

Must be nice to have the part out on the bench. Broken bolts for me are always exhaust manifold bolts on v8. Cannot take the whole cylinder head off. Usually can’t get in straight, frame shock etc in way. Have to use right angle drill. Can’t get right angle electric dill have to use air drill , can’t slow down that way. Bolts and taps never break way down in the hole where I can use a guide, always break right at top , smooth. Many times customer has already tried to drill and wallowed out the hole to an oval before I even get to start. Nice demonstration, but not really real world.

[@mikemiller373]

I used a "rescue bit" to drill out a broke ez out on 6-71 blower cover. Was replacing the allen head plug with a vent button. Those rescue bits are worth every penny.

[@ultimatehandyman]

👍

[@josephzager3871]

What is the paste you use to coat the bits? It sounds like "cooking paste" (but my hearing is not as good at 68 as it was at 28.) These are great videos. Thank you so much!

[@ultimatehandyman]

Sorry, my accent does not help. I used cutting paste, but drilling/tapping fluid will also work. exact cutting paste- fave.co/2Nabyxc Thanks for the comment 👍

[@josephzager3871]

@@ultimatehandyman No, Thank YOU!

[@mk4gli26]

I need this done my man tell me ur local 😩 6.8 ford engine 6 broke Studs I can’t get them out

[@carlguinesso3136]

How about turning the casting on it's side and dribbling water into the work to keep the bits cool and somewhat lubricated in order to make the task faster and easier ?

[@JohnHughes2002]

Purgatory for engineers!

[@ultimatehandyman]

Thanks for the comment 😉

[@Patrick_Gray]

First off excellent job of showing how to get broken bolts out. I owned a radiator shop and we had to fight broken bolts in aluminum radiator tanks. Steel bolts in aluminum radiator tanks would seize in. The bit you used and the bolts you made are great. I would have bought them. I have a few other ideas. 1. If you had the hole pointing up you could have filled it with water or WD40 so you did not have to dip so often. 2. Snap-On makes a kit with reverse rotation drill bits. It comes with guides that center the hole. They are not as nice as the bolts you made. They are not threaded. But the screw extractor that comes with them is custom made for the drill bit size and works better than the tapered screw extractor. 3. I have heated up the broken off tap/bolt and let it cool slowly to soften it up. Then drilled it out. The cobalt bits are good but they are also prone to break off. 4. I have welded a nut on to the broken bolt with TIG welding and heated and backed it out. 5. I really like HeliCoils, they work great. 6. I have drilled out a bolt and moved up to the next size at times. Final note: You could sell the bolts you made. I am old and retired, but surely would have bought or tried any new items to make a task like this easier. Keep up the good work!

[@ultimatehandyman]

Thanks for the comment, Patrick 👍

[@1pcfred]

What you ran into is called the galvanic effect of dissimilar metals. Something to do with the covalent bonds of the atoms being different between the two metals. In effect they make a weak battery. Along with making a battery they corrode like a battery can too. Aluminum oxide is what sandpaper is made out of. So it's some pretty hard and abrasive stuff. Oxides being brittle can be used to advantage. Sometimes you just have to shock the monkey. Impact beats torque.

[@mikebarger3563]

@Ultimate Handyman; I've got a broken off screw extractor that is flush with then end of the bolt hole. The hole size was for an M5 bolt. What size holesaw would you recommend? Any ideas for keeping it straight when drilling since I can't make a bolt drill guide?

[@ultimatehandyman]

M5 will be really difficult, as it is so small. It might need drilling out on a drill press using a solid carbide drill bit. I don't think you can get diamond coated hole saws small enough! Thanks for the comment 👍

[@tommymckay4666]

Sometimes you can get lucky using a left hand jobber. Depending on the material to be drilled of course.

[@ultimatehandyman]

Left handed drill bits are brilliant, but unfortunately they won't touch a tap/screw extractor. Thanks for the comment 😉

[@BarriosGroupie]

could you do a video on how to get hold of a competent handyman like yourself?

[@ultimatehandyman]

Sorry, its no good asking me that! In 2004 I had a house that was about 25 miles from where I lived. I phoned a builder, drain un-blocker's, a plasterer and a gardener, three of them never turned up and the builder tried to sell me a re-roof - which was not required. This was why I started my website- www.ultimatehandyman.co.uk/ In the hope that it will help to prevent people from being ripped off. Personal recommendations are always best, as I have heard bad things about some of these recommended tradesmen type websites.

[@dannydobbs669]

Really enjoyed this video thanks for sharing it. I run into this stuff all the time I use a good cement bit to get the broken taps and exactors out also I really liked your bolt guide idea. Much RESPECT!!!!!! ✌🏻from Ga.

[@pierreaugustin154]

incredible but sooooo long! could you explain how to remove titane bolt in a 2 piece bbs RS722 rim please?

[@ultimatehandyman]

You should be able to drill that out using a Cobalt drill bit Thanks for the comment 👍

[@Reno420alex]

I love you!!!!! This video saved the motor in my truck. I would have never thought about using a diamond coated hole saw... worked great!! Thank you so much (new subscriber here!!)

[@ultimatehandyman]

I'm glad the video helped Thanks for the comment 👍

[@TwistedEngines]

Outfuckingstanding. Learn something new every day Well done mate . Well done

[@ultimatehandyman]

Thanks for the comment 👍

[@javierrodriguez-vo8yr]

Yes this was very educational. I'm partway through a job. Don't know about my next step. Very hardened large steel bolt. Using carbide bits. May resort to a diamond hole saw but many videos say they don't work good? I've used them in the past and they really helped with broken taps, and extractors. Keep up the great videos!