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I'm trying to replace my hotend with the E3D Hemera direct kit. I got to the final step of hot-tightening the hot side and managed to snap my heatbreak. The part that screws into the heat-sink is stuck, though I was able to remove it from the heater block section.

Below is a picture of the heatbreak. The red square shows what it in the heat-sink. It's mostly thread (with thermal compound) but a bit of the unthreaded metal is sticking out (above the disk shown).

I've tried removing it with a jeweler's drill (which is how I removed the heater block portion, but I cannot get a good grip on the long threaded piece. I've also tried pliers and rounded needle-nose pliers. Neither worked. I couldn't find my regular needle-nose and will go to the store to try that. Are there other options to break this free or am I stuck with buying a replacement heat-sink? I already ordered a replacement, but it'd be nice to have a backup in case something else goes awry (as has been the case with this modification; this is snafu number 4).

Heatbreak with stuck portion highlighted

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  • $\begingroup$ Maybe you can add a photo how much is stuck in the radiator? $\endgroup$ – 0scar Jan 6 at 20:43
  • $\begingroup$ I can try when I get home. That's why I included the current picture. In the box only the unthreaded portion at the top is sticking out. (About 1/4 inch of metal) $\endgroup$ – Lux Claridge Jan 6 at 20:44
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Broken screws or screws with damaged screw heads are typically removed with screw extractors. Since there is already a hole you could "drill" (unscrew) it out with a screw extractor, as it is counter clockwise, it is about creating enough friction to unscrew it from the threads. Beware that it is not drilling and spalling material, turn slowly.

enter image description here

Alternatively, a grip vice pliers may work if there is enough "meat" to clamp on.

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  • $\begingroup$ Never heard of the extractor before. Nifty. Are there any particulars that I should concern myself with? Namely the fact that there isn't much metal due to the aforementioned hole and what size of extractor I should purchase. Since the Hemera uses tight tolerances and came as a kit, should I remove the dual gear assembly? $\endgroup$ – Lux Claridge Jan 6 at 20:50
  • $\begingroup$ I'm definitely googling how to use an extractor, but I doubt I'll find anything that is specific to 3D printers, asking so I don't miss anything that definitely won't be covered elsewhere. $\endgroup$ – Lux Claridge Jan 6 at 20:51
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    $\begingroup$ @LuxClaridge It's all about creating enough friction to unscrew it, you could also fill it with hard wood and use a smaller extractor. Usually you buy them in a set with multiple sizes. $\endgroup$ – 0scar Jan 6 at 21:03

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