"Dave Plowman (News)" wrote in message
...
I've got a couple of very small self tappers which have broken off flush
with a blind housing made of thin mild steel - car bodywork. Due to being
rusted in place. What's the best way to remove them with minimum damage to
the bodywork?

I had a similar experience with the door handle screws on a Golf. In the end
there was a combination of plus gas, time, cutting slots with a dremel and a
drill. I think the slots and plus gas eventually did it. I find using a
torque limited cheap electric screwdriver useful for these sorts of things -
set them to a low torque setting and high speed and you get a very light
impact driver effect that tends to get things moving. Drilling was something
of a waste of time - the screw must have been made of something tough as it
blunted drills like crazy. The heat may have helped a little though -
couldn't use a blowtorch due to the still attached plastic handle.