2006 GL1800 Luggage Rack Broken Tap

[echinus1988]

I noticed a broken bolt on my luggage rack that sits on top of the trunk about a month back. I figured I'll have to use an extractor to get the bolt out and be very careful doing it.

The problem is, the bolt isn't broken. The tap that was being used to put in threading for a new bolt is snapped off in the luggage rack.

So, an extractor won't work. I don't have any pliers small enough to fit in the hole without messing things up more. The only solution I see is to take a dremel and bit and carefully grind it out. Maybe a diamond bit with a very fine tip.

After getting it out, drill it, tap it, put in a helicoil so I can screw a bolt in.

Any other suggestions? I am open to consider anything.

[keithg64]

A carbide tool on the dremel may work but the tap is probably deep in the part. Taps usually will brake when you start to back it out.
Is the tap broke off flush with the part ?

[Steve F]

I've been a toolmaker for 45+ and when we break off a tap, you can sometimes use a tap extractor designed specifically for the size tap you have broken off. If it's a 2-flute tap, maybe 5mm you get an extractor for that tap. They're available in 2, 3 and 4-flute varieties. If that doesn't work we would resort to a machine that disintegrates the tap into pieces that can be picked out of the hole. The machine is called a DISINTRODE and uses EDM process. Many machine shops have them, but not all. Go to MSC or GRAINGER or maybe McMaster-Carr to find the tap extractors. Search local directories for machine shops in your area. Use the DREMEL as a last resort because you'll probably mess up the threads with it.
Regards,
Steve F

[keithg64]

The tap extractors, yes.
As a journeyman machinist I have also used a tap burner. It has an electrode that burns the tap out. I have drilled out taps too with a carbide end mill.
Either way a machine shop is the place to go if the extractor doesn't work.

[echinus1988]

This is why I come here. The wealth of information is amazing!!!

The tap is broken off just a touch above but not enough to get a hold of.

I'll look for the tap removers since we have a Grainger close to me. Well, close to a little restaurant that I like...

If not, I will talk to a machine shop and ask them. I'll talk to my cousin also. He has a shop that makes parts, mostly aluminum, and may be able to help.

Thank you all for your input.

Ride safe!