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rounded off screws
andrew-theasby - 16/5/11 at 07:41 PM

I need to remove 2x 5or6mm countersunk screws from blind holes in a thin alloy engine casing. Any tips please ive already rounded them off, and tried one of them impact screwdriver thingys, its been soaking in plusgas for a few days now but im not convinced the small easy-out will get it, so before i do any drilling, was wondering about welding a nut on but not sure i could do it with such a small nut required and also the engine casing will only be made of toffee so i dont want to melt or distort that

Peteff - 16/5/11 at 07:52 PM

If they still have the heads on you should be able to weld to them if you are careful. Aluminium should help to dissipate the heat. Failing that don't bother with easy outs just drill as much out as you can and use a tap to clean up.

andrew-theasby - 16/5/11 at 07:55 PM

quote:
Originally posted by Peteff
Failing that don't bother with easy outs just drill as much out as you can and use a tap to clean up.


How would that work? Ive heard people say that before but wouldnt it just nacker the aluminium thread?

rusty nuts - 16/5/11 at 07:55 PM

Left handed drill bits or screw extractors

big-vee-twin - 16/5/11 at 08:09 PM

You need a BOA extractor

monkeyarms - 16/5/11 at 08:30 PM

Weld a large repair washer to the head of the screw, then weld a nut to the washer.
The washer makes things a bit easier.

BenB - 16/5/11 at 08:38 PM

I would stay well away from Easy-outs. The fact that you've rounded them off shows they're seized. Easy-outs are not supposed to be used for seized fixings, just fixings without a head. If you use an eazy-out you'll end up having to drill it out to. Guess how I know I've always found the welding trick worked nicely. Depends what the screw is made from though I guess...

andrew-theasby - 16/5/11 at 08:47 PM

ok thanks, ill try welding first then, i like the washer idea! Got plenty to go at now as ive just sheared another stud chinese junk!

Thurbs - 17/5/11 at 08:36 AM

Drill off the countersunk head and get some grips on the studs when the covers removed (hopefully !!) at least reduces risk of damaging cover if further methods needed.

RickRick - 26/5/11 at 08:20 AM

tip for tight screws, before you round the head off, put a spot of grinding paste into the screw head, helps the driver grip

Daf - 26/5/11 at 09:26 AM

quote:
Originally posted by RickRick
tip for tight screws, before you round the head off, put a spot of grinding paste into the screw head, helps the driver grip


I've never heard that before, how does that work? Brilliant tip if it works

locoboy - 12/6/11 at 07:34 PM

I have used this top tip before, it is an abrasive paste so essentially it provides additional 'grip' between the screwdriver and the part of the screwhead that the screwdriver contacts.