Update in case anyone was wondering how things turned out. There was two pieces of metal in the hole. One from the tap and one from the stud. Took me a few hours with some dental drill bits to remove the metal from the stud. Worked blind most of the time using a mirror and feel. Retapped to a 9/16 -...

Very Nice set up.

I cut down a bit. Tomorrow I'll use the old manifold as a guide and drill the hole. Hopefully I'll be able to tap this without breaking the tap. It's a pretty big tap so I'm not expecting any problems. Plus I only have to go in about a 1/2 inch.

YAHOO......!!!!!!Got it out. The Walton tap extractor worked great. Took about 5 minutes to get it out. Thanks everyone you all really helped. OK next question the hole is pretty much mucked up. I'm going to drill it and tap to 1/2 x13 for a threaded insert that I like Problem I can only get a Drexe...

Can't get in there to even hit it with anything. I ordered a tool to try and turn it out. See what happens when it gets here.

Thanks everyone for all the tips. I really appreciate it.

Thanks Len I'll check them out.

Greentree....about 5 minutes from downtown.

Thanks Dave for that link. I'll give that a try.

Yes aluminum head. The hole is going to need a helicoil so not so worried about the threads, Just need to get the tap out.

Hi All,

I seemed to have broken a tap in the worst place. 2005 F150 with a 5.4 motor right side exhaust manifold stud hole in the head. It's about a half inch in the hole. My question can I stick weld to the tap and build up to a nut to turn it out? Thanks for any suggestions.

Terry

Hi Everyone, I'm a long time mechanic from the Burgh. Work for the Worlds' largest fleet USPS. Been stick welding most of my life. My uncle showed me how when I was a wee lad. I only found this site because I have a problem that I think the only way to fix it is to weld it. I'll post it to the right...