So I'm drilling my driver's side manifold when all of a sudden, the damn tap breaks off inside the manifold. Luckily, it broke off at an angle which left about 1/8" that I could grab, very gingerly, with a pair of pliers and back it out. Luckily, I got the broken off piece out. I don't think anything fell into the exhaust since it was running. Sure scared the Censored out of me when it happened. All I could see was that piece getting sucked into the turbo and grenading it! It had also gone deep enough to get a good tap. That was only the second time using this tap too. I have never had that happen. How about anyone else?

Chip in the tap hung up the cutter teeth ??? maybe

It's the cock-eyed angle, necessary for the job task - requires more facial contortion and tongue-biting than when tapping directly straight-in.;)

Final effect would result from the piece being 'blown' into the turbine blades, or could just rattle around in the c-o pipe, driving you nuts.

Good recovery........

Did the drill or was it the tap? Had plenty of drills break but never a tap. I also do no use a drill to turn the tap.

Here is a question. When doing the pre-turbo tap how do you keep the little chips from going into the turbo?

Here is a question. When doing the pre-turbo tap how do you keep the little chips from going into the turbo?
That's why you make the tap with a running engine. It blows the shavings out the hole your tapping. Right guys?

dkubek, I did the SAME thing you did. Barely got it out.
I was tapping a small square casted right below the turbo flange. It looked like the perfect spot. I think I just got a little crooked.
I too, only got half the threads I would have liked to have had, but she seems to be ok. No leaks.

It was wierd. I was turning the tap with a straight tap handle obviously due to lack of space and it just broke off. Here is a pic of it. Needless to say, I will be returning it to SEARS.

Yah, steel seems not what it used to be, nowdays.

And yes, the engine was definitely at idle. It is actually idling at about 1100rpm right now(see other thread). I think that may have been a good thing all things considered for this near catastrophe. I was moving my probe to try and get more accurate readings since I turned the pump up. I think it happened since I was doing a dry tap. I didn't want to get any lube in the turbo. I don't know if it would have mattered or not. Did anyone else use cutting lube when tapping their exhaust manifold while on truck with engine running?

Yah, steel seems not what it used to be, nowdays.
You ain't lyin'. My Dad's hometown of Ambridge, PA used to be a huge steel town. Now all the factories my grandfather worked in are all closed up and their "steel making components" are being disassembled and shipped overseas:eek: ! How about that price of steel, huh?

So you drilled and tapped with the engine running?

I didn't use any lube or break a tap, but of course it was done on the bench not in the truck and i tapped the boss below the turbo, i don't think i'll see much of a temp difference from where you guys are doing yours as my 2.5" x-over was painted black and has 2 coverings of header wrap and then painted black over that again.

Taps are very hard and if you apply force in the incorrect direction can break easily...

You ain't lyin'. My Dad's hometown of Ambridge, PA used to be a huge steel town. Now all the factories my grandfather worked in are all closed up and their "steel making components" are being disassembled and shipped overseas:eek: ! How about that price of steel, huh?
I dunno 'bout steel, but leads going out at 44 cents a pound :rockit:

This makes for a happy Timmy!

Tim

Taps are very hard and if you apply force in the incorrect direction can break easily...
That must have been what happened since I was using a straight tap handle (like a screwdriver handle) to do the tap. A lot harder to apply perfectly perpendicular force. Oh well.