"Nick Leone" wrote in message
...
I seem to recall from the book "machine shop trade secrets" a procedure for
broken tap removal that looked promising. His suggestion was to use a
round peice of carbide (in your case, probably 1/16") and grind a spade
shape in the end of it. From there, mount it in a mill and VERY slowly
feed it into the tap. It will (supposedly) cut right through.

That said, I've never tried this procedure, and 1/16" tool won't be very
rigid.

Do you have access to a wire-fed EDM machine?

-Nick
snippage about a #2-56 broken tap in bronze

A wire feed EDM isn't gonna do a lot here...the chances of being able to get
a wire through, on location, aren't good. AND that's assuming that OP even
has a through hole.