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What to do when a tap breaks in a hole??

Either way you do it the threads in aluminum are going to be messed up - can you weld it back up and re do the hole? Can you make the hole / thread bigger?

I did remove a tap once by TIG welding metal to the top of it and then just going backwards. This is by far not easy as the heat from TIG makes it brittle - you have to try to heat it a bit longer and anneal it.

With M3 size this will be very tricky to do - that sucker is tiny.
 
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