"Bob La Londe" wrote in message
...
There is a cracked set screw in one of m Kwik 200 tool holders. It's
a 1/2 inch holder so its one of the most common and cheapest to find
used. That being said there aren't as many used Kwik 200 tool
holders to be found on the most obvious source (Ebay) as their used
to be. I hate to pitch a tool holder I already have over such a
cheap part.

Here is the problem. There is a tool in the holder and its well
secured. I want to take the tool out, but even a clean crisp brand
new hex key just pops around like the screw is rounded, but its not.
I'd like to save the tool in the holder other wise I might be
tempted to press it out.

Is enough of the screw exposed to cut it off? The ends of dull hacksaw
blades are still sharp and can be ground thinner on a wheel that's
dressed straight, or better on a surface grinder. They also make good
flat springs with a mounting hole.

Try an English hex bit if it's metric, or vice versa.

Perhaps you could grind the end of the next larger size hex bit until
it can be jammed in. Just shorten the modified bit to restore it.