On 2010-06-03, bobmct wrote:

I've tried a couple of tpical screw extraction products such as ones
from Harbor Freight and HD, but they both sucked and actually broke
while trying to use them.

Never buy discount/tv screw extractors. I know the hype is often
overwhelmingly alluring, but it's all crap. Screw extraction is
tricky, exacting, and fraught with pitfalls. If you want to avoid
costly last-ditch methods, pay attention and spend the $$$ up front.

I figure, if one purchases something that actually works, it worth the
investment rather than buy junk only to throw it away and still have
the problem to solve.

Good attitude!! ...and dead nuts on!

First, buy a quality screw extractor system. I'm talking quality
extractors made of high quality steel and requiring drilling a proper
hole first. There are two main types. One is a square shape with
little flutes at each corner. The other is a reverse spiral. Both
work equally well, but require a precise pre-drilled hole. Typically,
both have a square headed drive and require something like a T-shaped
tap handle to use properly. I realize this sounds costly, but not as
costly as failure.

These can be found at machinist tool supply outlets/shops. Again,
better to buy the good stuff, even if you have to do so online. You
might also check an automotive parts store. Auto mechanics are always
doing broken bolt removal and auto parts stores usually carry pretty
good quality screw removal tools. Try your local Napa store.

Second, make sure you have good drills and a center punch. Punch a
center. Take your time and be as accurate as you can. Drilling an
accurate and straight hole is the primary KEY to success. Use quality
high speed steel drills (HSS) to make the hole. Use a good cutting
fluid to make a clean hole. It can't hurt to soak the hole/screw with
all kinds of lubricants and bolt derusting/breaker solutions. Also,
make sure you drill the right sized hole for the screw/bolt size and
correct extractor size. Fudging is a sure-fire prelude to failure.
Finally, tap the extractor in with a small hammer to get a secure
grip, attach the handle, and begin the extraction. If you have
proceeded carefully, methodically, and accurately, you should meet
with success. If not, there's always EDM ....electrical discharge
machining (the costly last ditch option).

OH.... one fellow recommmended a reverse or left handed drill. Can't
hurt and sometimes it works, specially with smaller screws. If you
want to try it, again drill an straight accurate hole. It will either
work and back out the screw ...or not! If it doesn't remove the
screw, at least you will have a proper hole to proceed with the
extractor tool.

Good luck!

nb