Small broken screw extraction

[LavaTech]

Some of you may encounter (or already have) a very small screw broken flush or below surface level in a blind hole, such as the front sight screws or magazine catch screws (#3-56) in the rear receiver block of early Remington 513T rifles. Now to be perfectly honest, my favorite first step in this typically two step repair process is to drill the pilot hole for my screw extractor with a left hand cut drill bit which often will do the job before the pilot hole is completely drilled. The next hurdle if the pilot hole drilling didn't do it all, is the extractor. EZ-out extractors don't exist (as far as I'm aware) for the very small screw sizes, but dozens of manufacturers make others, calling them "Torx" drivers or bits.


Whatever number size drill bit is fractionally smaller than the O.D. of the Torx tip diameter will typically do just fine. The flare at the top of the driver or bit can really save your bacon if you cut the pilot hole a bit on the large side, too.


Perhaps I'm trying to reinvent the wheel here, but I thought this could be a lesser known but effective workaround to share.

[broomhandle]

Hello LavaTech,

Yes Sir, that will work very well!
The big trick is to have a sharp center drill to start the hole. Make sure the hole is on center and straight as you can make it in two directions!
We usually insert a longer screw into a near by hole as a reference point. I always mount the barrel in a vise and lock it solid to the table. Lock everything down, so it does not move from the intended hole.

Thanks for the reminder,
broom

[LavaTech]

Thanks right back at you. It's always good to have more information, it beats the snot out of less! Besides, this two step process was needed to make up for my oversight in not giving your very sound precautionary advice myself.

[Garandpa]

Another option is EDM (electronic discharge machining) which some machine shops can facilitate. I't's no doubt more expensive than the above methods, but it can salvage a situation where the other methods might not perform well.

[broomhandle]

Hello Garandpa,

Yes Sir a fellow at one shop I worked at had permission from the owner to do a few jobs on the side after working hours. I think we can buy a low cost chinese machine to do stuff like that . I recall seeing some online.

It's good to be a Grandpa, spoil them and send them home!

Enjoy every day,
broom