[newtattoobob]

I decided to move my pyro from the block off plate to the manifold. I was able to drill the manifold easily and when I was almost finished tapping the tap broke off. I tried everything I could think off to get it out but had no luck so I pulled the manifold and burned it out with a torch. Now I am having trouble retapping the hole. I think some of the tap must have melted into the threads because a new tap won't touch it. Will I need to drill it out bigger and use a reducer from 1/4 pipe to 1/8 pipe? Any ideas? Also when I pulled the manifold the gaskets fell on the floor and came apart. I think there should be four for each port? I also see some have tabs on the outside and some don't. does anyone know the orientation of the gaskets? Thanks

 

[BigJonB]

Always use wax when tapping - idk about the tap melting but it's possible i suppose?? Also snap on makes a nice tool for removing broken taps. It has "fingers" that fit into the flutes if the tap allowing it to be backed out...I know a little late now...
I'd try retapping the existing hole with a fresh tap and plenty of wax...

 

[cntryby]

The heat may have harden the metal.

Weld a pre-drilled & tapped plate to the manifold, or do what you said and use a reducer bushing.

If it was mine I'd get a new gasket.

 

[newtattoobob]

I did buy a new tap but I can't get it started now. I can still see some of the threads I orginally cut but for some reason I just can't get the tap to start. Thanks

 

[stargeezer]

I'd drill it out and tap to 1/4 npt and use a reducer. Don't drill it out one big step, two or three steps will help you keep from oval-ing the hole. I've never used wax for tapping, I use a thread cutting oil that plumbers use when threading pipe. Wax may work fine, I've just never heard of it paraffin is a oil byproduct.

If you are equipped for welding, I'd be tempted to weld the hole closed and start fresh since you have the manifold off. My son gets calls to weld cast from his buddies a lot right now, most weld shops could do it pretty quick. Drill the new hole as far from the old hole as practical.

 

[2500MegaDiesel]

Johnsons stick wax number 140. Best cutting lube ever invented. Will keep stainless on stainless from galling.

 

[bbt82z]

Are you using a tapered tap (aka starter tap), plug tap, or bottom tap? If you think there are pieces left in there try using an o-ring hook set to see if you can break it free, then use the threaded tap.

 

[cumminalong]

Okay, for those that have never seen one before, get a tap extractor, takes all of 5 minutes....

Tap Extractors for Machine Screw, Hand, Pipe & STI Taps | Walton

 

[BigJonB]

Johnsons stick wax number 140. Best cutting lube ever invented. Will keep stainless on stainless from galling.

+1
oils good fir drilling and cutting but for tapping-WAX!

 

[DRT086.7]

You could always drill it bigger and use a threadcert, they dont have to be tapped to go in. I have used them on manifolds with broken turbo studs, they work great.

 

[newtattoobob]

I am using a starter tap but I just can't get it to start. I am going to look at the hardware store for the thread inserts, I didn't think about that. I know they make them for bolts and machine screws but I don't know about pipe thread? I don't have access to a welder or the know how to use one. I do have a small machine shop close by, I think on my way to the hardware store I'm going to stop there and see if they can do something with it. Thanks.

 

[juicedCTD]

I had the same thing happen. Welded the hole up and drilled another hole. Ran it like that for 70k. No problems

 

[newtattoobob]

I got it fixed. the machine shop was able to drill it out and tap it 1/4 pipe and I used a reducer bushing. Now I just have to wait for my new gasket. Thanks for all the suggestions.

 

[jpen3183]

I too made the same mistake. Took off the manifold and dropped the gaskets and some came apart. Manifold went to an engine rebuilder who worked his magic and $50 later it was fixed. I asked him about gaskets and he said to reuse. No problems yet 15,000 mi later. I did use anti seize on reassembly just in case I had to remove years later