Chasing out a broken 1/8 NPT thread

[Grega]

Well I scored one of those moments which you really don't wanna find.
I had an alloy T piece in the side of my 2T - one feeding the turbo oil supply, the other for a sender.
The T had a 1/8 NPT fitting going into the block (FWIW i think the 2T and most Toyota fittings are 1/8 BSP) which kindly snapped cleanly at the block face - not a pleasant sight.

How to get it out ; well I had it reasonably easy as the motor was NOT in the car.

Parts needed
1. Drill
2. Metric drill bits
3. 1/8 NPT tap
4. Patience
5. Beer (for when the patience runs out)
6. Small flat blade screwdriver
7. Long nose pliers
8. New sender

OK

Starting with the smallest drill which fits inside the alloy fitting, drill squarely into the bit
Make sure the drill is square
Move up to a 6.5mm drill bit which will eat out to the thread the alloy T piece
Pick out the pieces of alloy with small flat blade driver until its clean
Crank motor and clean out the oil gallery of all alloy shavings (important) - this will push oil OUT the oil sender location - be warned
Put 1/8 NPT tap into sender hole and wind in about 8 turns.
Pull tap out
Look for piece of alloy to grab with long nose pliers - if possible grab and remove
Crank engine again to push out crap threads of alloy with oil
Check sender for fit - should be all good
(If not, inspect thread, re-run tap and see if you can get some more alloy out)

This is a bugger of a job if you ever come up against it.
I didn't have an ezy-out
Although I did try to punch it and rotate it out with little success.

Hope this helps someone....

[love ke70]

should help someone, good work
ive never found easy outs to be of much bloody use anyway, drilling and tapping if accessible is the best method. doing it in a bench drill is even better

[allencr]

Pack grease in the flutes of the drill & tap to hold most all of the chips.

[Grega]

allencr : another piece of good advice there. good stuff.
something else to bear in mind ; remember to keep an eye on the level of oil in your motor as i tell you what the old oil pump really pushes some oil out that little hole!