Drill-Outs & broken Threaded Attachment Removal

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Damon Evison
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Joined: 2011-08-04

I have recently acquired an old industrial air compressor. It has a big  250 ltr tank and a 200psi rated output.

Unfortunately the regulator output port has snapped off, leaving the threaded tube connection embedded in the end of the tank. The internal diameter of the connector is 12.7mm (1/2"). Too big for a 1/2" Drill-Out extractor drill bit, which is intended for drilling into solid material (i.e. bolts and studs) up to 1/2" diameter. HELP!

How do I remove the broken connector? I have started applying penetrating oil and intend to use a heat gun to try to ease the grip of the thread surfaces, but I dont know what to use to grip on the internal face of the tube. Are there larger Drill-Out bits available other than those by manufacturers such as Alden and/or how else can I try to remove the broken connector?

I am loath to simply try to drill the connector out with a hand held drill. Damaging the tank thread could massively affect it's integrity and strength, but would give it a go if there is no other way.

Anyone else had a similar problem?

Thanks 

Damon

Damon

Damon Evison
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Joined: 2011-08-04

OK. I've applied loads of WD40 and penetrating oil, I've applied heat (butane burner) and used a 15mm reverse thread bolt remover. The bolt remover wound its way all the way in (and pretty well rounded it's square shank in the process, and I broke a spanner. But the connector still hasn't budged. I guess that means I now have a 15 mm hole...

What to do?

Damon

martin thaddeus
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Joined: 2012-05-23

 

Hello

 

What is the offending piece made of?  If it is steel you could consider mig welding a bar across it,  The heat soak will break the tension and the bar can then be used as a handle.

If it is brass or some other material you could consider solder it there is enough left to get a grip on.

 

Good luck.

THADDEUS