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stuck set screw

L

Lee in Iowa

Member
Anybody have any good ideas for getting out an allen head set screw that"s about 1/2 inch recessed in the hole and rounded out? It"s been soaking in PB blaster for about two days and I tried grinding the next biggest size allen wrench down but I still can"t budge it. Thanks in advance. Lee
 
I screwed a nut on the end of the set screw sticking out then welded it to the set screw, then used an impact to remove it without any problem. Even if you cant screw on a nut just get a nut the same size as the set screw and hold it with pliers up to the set screw and weld. A new set screw will be in order anyway.

Todd
 
if you can try to reach in and heat screw red hot with torch quickly and just the screw .if you can 99% chance screw will come right out.another option would be drilling screw out.Paul
 
Get another allen wrench a little larger and grind a slight taper on each side at the end. Drive it into the screw and back it out.
 
Everybody below has ideas for getting ahold of it. To loosten it up,heat the area around it good and hot,then hold a piece of wax up against it over the hole. The heat will pull the wax in to the threads and lubricate them. Let it cool,then use somebody elses idea to get ahold of it.
 
I've seen the wax paper trick done before and that should help you get it out. You might even be able to use the ground down allen wrench you already made.
 
if you got room, just drill the stupid thing out.
start with a bit size that fits snug in the allen hole to keep it centered,then use one that fits the treaded hole snug[will leave the tread intact] if the screw is grade eight,tap the trigger on the drill on and off and keep downward pressure on it,to prevent burning the bit. that will eat that screw in a hurry.

an other trick i use on a stuck screw is to use a punch that fits the hex hole snug and give it some good raps with a hammer,before i wreck the hex.and allways use w-40 beforehand
 
Allen set screws are very hard. And so hard to drill. A left hand drill bit is sometimes better than a standard drill bit because if it catches it can spin the remains of the bolt out of the hole.

Kroil is sometimes more effective than PB Blaster.

And article in Home Shop Machinist last winter claimed a mix of acetone and ATF was even better. I've not tried that one yet.

Gerald J.
 
Get a slightly larger metric allen bit and see if it can be hammered in. Don't hammer it in just yet tho... Now, heat the set screw until it's red, then hammer the bit into it. Turn it out...
Do it hot. Don't let it cool or you're back to square one.

Rod
 
Torx bits are perfect for this - you can hammer in the bit, & it will cut its way into the grub screw, then use heat & the socket bar to remove it.
 
I'm with bison, just drill it out, should be a lot less work than all the other suggestions combined.
 
I had a flat-belt pulley on a Wis engine that I needed to get off so I could put a vee pulley on the shaft. The allen head was broken. I took the centerdrill out of a small holesaw after I sawed a hole in a piece of scrap. I clamped the scrap to the pulley and used it as a guide instead of the drill and sawed thru the pulley to the shaft. When I rotated the engine the piece fell out and I pulled the pulley off with my hands. I didn't need to save the pulley but I could have by tapping it for a bigger set-screw. HTH
 
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