I recently broke a tap in a newly made aluminum power steering bracket for my 1929 Ford Hot Rod. Several methods of removing the tap failed. Upon a bit of research I discovered that the tap, drill bit, or even a steel screw/bolt can be removed effortlessly by boiling the aluminum part in a water and alum solution without destroying the aluminum part. This was so simple and worked very well.
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This video shows why using an R-style lynch pin in place of a standard cotter pin is a bad idea.
Sorry for the video quality. It was filmed in a dark garage without enough light.