NPT thread Tap broken in Cam Tower

[thomas682]

Is this as bad as I think it is???

'78 Turbo cam tower - I was successfully taping the spray bar plug ends in the cam towers to install the NPT removable plugs. First three plug locations were taped without any issues. On the last location I needed another 1/16" cut in to allow the plug to be flush with the face. As I was backing the tap out for the last time it snapped off almost flush with the face of the tower. Any suggestions as to how I might remove this tap? There is not enough exposed to grab with vice-grips and I do not have a drill press and doubt that attempting to drill out the hardened tool steel from the aluminum cam tower is a great idea? Is it common for taps to break? I was using a mix of grease and penetrating oil as a cutting lube and frequently flushed out the cut materials.

Thanks in advance for any suggestions or sage advice as to how I might best deal with this mess. Photos below...

[jlex]

Weld on a bolt head to allow you to turn it out? Others will know...

[rwest]

They make a special tool for that- tap extractors. https://www.mcmaster.com/#tap-removers/=174l4xh

[boosted79]

Yes, find a nut that slips over the end and have someone mig it to the tap.

[cabmandone]

The plus side is that you still have material to work with. Did the tap stop going through or did it break on the way back out? I had one bind on the way out and snap. If this is what happened I'd see if you can get it to thread back in and use air to clean the blockage. I don't think I'd try vise grips on it as taps are hard and hard=brittle.
BTW, I feel your pain. I had a forming tap snap off in my block. I went through every stage of dealing with grief and then learned how to install time serts.

[turbo owner]

It can be burned out without damaging the aluminum, EDM machining is one method. Contact a machine shop or speed shop for references.

Ollie's did my machine work and they sent a case 1/2 out somewhere for head stud removal.

If you try a DIY and things go bad, you will spend more fixing it than you would if you paid upfront to get it done right.

[Jcslocum]

There does look to be enough to grab it. You can hea that e cam tower to expand it and loosen its grip on the tap. Welding a nut will allow a best grip, but wait for it to cool!

[Joe Bob]

Go with the EDM, let the experts fix. Too easy to bugger it up.

[yelcab1]

Well, at least that thing is outside of the engine and can be taken to a shop for EDM. For me, I would weld a nut on top and remove it.