Contour Enthusiasts Group Archives Forums Modifications General Mods Hood strut instal gone wrong

So I got some struts off a taurus and finally found all the hardware I needed to do the instal.

Well while working on the hood and drilling out the hood mount screw and tapping it I've enountered the worse thing possible. The tap sheared in the hole and is stuck right in place. The material used for the tap is so hardened that bit after bit after bit after bit just dulls out trying to drill it out.

Now I'm left with a hood with 1 strut installed on one side and 1 screw ont he other side and a bummed hole.

I've contacted IRWIN (the manufacturer) about a claim since this was a brand new bought today bit and tap kit. Thus the hole I was tapping was the perfect size because the bit I used before tapping it was from the same kit.

This just sucks, any suggestions?

Is there enough of the tap sticking out from either side to get some pliers on it? If you can get to it, you may be able to back it out. I don't know how much room you have if if you have the welding skills, but sometimes you can weld an extension on to the broken piece and then still back it out.

Finally, if needed, have a welding shop or body shop cut the piece out and then fill the void or patch the area so you can try drilling and tapping again.

the only thing i can think off is to take the hinge off of the hood on that side and then you should be able to get some vice grips on the end and back it out.

thats the only thing i can think off at the moment

maybe some pics of it might help

There are broken tap removal tools, but they aren't cheap. They have 4 fingers that slide into the 4 grooves going down the body.

Sorry to hear that man... For future reference you should turn the tap 3 revolutions then back it up about one revolution to break the chip, and then repeat till the hole it tapped. Also use a cutting fluid WD-40 works great.

Did that and still sheared.

Just fooled with it for another hour and no dice.. Going to look for a tap extractor now :-(

Bought a tap extractor, expect it in any day. Hopefull I can salvage the hole and still put in the ball stud necessary.

WOW, finally fixed it and the hood struts are AWESOME

So I bought the proper 5/16 4 flute walton tap extractor online. It's arrives and on the first attempt the fingers shear off.

So I go back to Cleveland form Chicago with a black eye from the experience and a broken tap in my hood. I find a local tool supply warehouse and find out they carry the replacement fingers. I buy 2 sets remembering my prior experience.

The first of the new fingers shear off as well. I replace them with my last set and success. It felt like I won the super bowl.

It's official using a tap extractor is the most nerve wrecking tool to use in this world.

So after weeks it's all done and I love it! If it werent for the broken tap the total price is about 14$ for the struts, ball stud, and brackets and tap.

Glad to hear!