broken tap in fork

I got a 72 sportster, This occured while changing brakes on my front wheel. There are two bolts that come out of the fork at the bottom to secure the axle to the fork, one of these bolts broke off. So I decided to drill and re-tap it and replace with a threaded rod. Problem 1 is i drilled to high and released the fork oil out the bottom, problem 2 is upon trying top tap the new threads i broke the tap off in the fork. 1st of all any ideas how to remove the tap, and secondly upon removing it can i seal the fork again to refill with fork oil? My idea is to drill out the tap, fill with JB weld, and drill and re-tap. Hopefully this will seal the fork oil. But not sure how to get that broken tap out. Any help would be appreciated.

The only way I can think of getting the tap out is to try to get a slim pair of needle nose (or similar apperatus) on both sides of the tap and try to un-tap the tap. This will depend on how tight the tap is wedged into the fork sleeve. As far as JB weld, keep in mind that there is alot of pressure that is built up when you hit a bump with the front of the forks. JB weld will not hold back this kind of pressure. But lets say that your only option is to use JB weld, If you do get the tap out and re-thread the leg of the fork, the only way I can see to use the JB weld is to pack a bunch up into the threaded area of the fork and immediatly follow it with the bolt, but beware that if you go with doing it this way you'll probably never be able to get the front tire off again, because the treads combined with the JB weld will be permenant. Usless there is some kind of new welding procedure to get up into the place where the hole is to spot weld the puncture, I think that your best bet would be to change out the forks, especially when your talking about going high speeds down the interstate, you would hate to have your front end fail.

oops

Sounds like have a little problem there. First, if the needle nose doesn't work and you are dead set against taking it to a machine shop, braze a small rod to the tap and back out the tap then drill out the hole entirely, tap it all the way through and take a set screw to stopper the hole. Be sure to screw the set screw in far enough that your bolt doesn't hit it and put enough thread goop on it so it won't move. The smart money is on taking it in to the machine shop.

They do make a tool that is made to remove broken taps. The machine shop folks will have one, and I would bet they wouldn't even charge you to remove it. I've broken 2 and each time I took it to the machine shop the guy had it out in about 60 seconds. Told me it wasn't worth charging for.

After you get the broken tap out and the hole sized and tapped correctly while at the machine shop I would suggest using a stud the right length threaded in using Loctite 567 thread sealant. That will stop any future wear on the aluminum. Don't forget to have the machine shop center and drill the cap also.