Removal of Allen Screw with Stripped Head?

[JPG]

https://www.harborfreight.com/impact-sc ... 37530.html

Will need 1/2" drive to 5/32 hex.

[john_001]

You could try a screw extractor. You drill a hole into the head of the screw, then insert the extractor and twist counter-clockwise. The left-handed thread draws it into the hole until it bottoms out or locks up, then the screw starts to come out. With a stripped Allen head, you may already have enough of a hole for the right sized extractor to grab. I've used them to remove broken studs on a car engine, so they work pretty well.

[Dansmith]

Thanks again for all the tips.

I finally got it out after spending about an hour on it. I tried re-grinding my allen wrench and leaving a burr for filler. No luck. I tried the torx bits. No luck. I tried a bladed screwdriver bit. No luck. By this point I was way beyond leaving it in.

Went to HD and found a Ryobi extractor set for around $8.00. Tried it with 2 diferent sizes and after a very long time of messing with it, it finally came out stuck on the extractor (came off eaisily with pliers). All that was left was about a 1/4" of screw thread (bottom end of screw) on the extractor.

Only one casualty. When drilling out for the extractor, I went through the key. I could still use the key; but, I want to get a new one while I go buy the right lenght allen screw. The new ones I have are either too short or the pointy kind. Threads on pulley are untouched.

[Hobbyman2]

I picked up a assortment of set screws for the SS of different length on ebay,

[Dansmith]

I picked up a assortment of set screws for the SS of different length on ebay,

Thanks for the heads up. I have this very near to me local industrial supply house that stocks all sizes. Prices are very reasonable, like 25 cents. Often times they tell me its a waste of time to write up an invoice, and to just take the screw.
Almost next door to the industrial supplier is an electrical repair shop that might have a key for the pulley.