Who hasn't broken a tap off in the work? This time, the tapping was the last operation on a number of parts I made up for a job at work. Broke a tap below the surface - it was a 4-40 imbedded in a piece of 1/4" aluminum plate. Yeesh.
After a surprizingly difficult search, I located some alum (Aluminum Sulfate). Disolved some into water until the solution was basically saturated. Heated the whole thing up to "simmer" (not boil) and dropped the part in. Then I went and cleared the leaves from the yard and mowed the lawn. After about 4 hours of this, the only thing left of the tap was little undisolved parts that looked like pepper flakes. The aluminum was untouched. Woo hoo! I finished tapping the offending hole with a proper tap guide, and the part is perfect.
Thanks to the folks here. It may be old news to some, but it sounded hokey to me. After trying it, I can only say that it's like FM. (Freakin' Magic) The part (and my bacon) have been saved!
-Mark
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