^^^ LoL
5 holes out of 8! That's good enough for the girls I date...
You've got to have the patience of Job to do this....

Another vote for drill it out and retap the threads

I've had the best luck with the "Easy Out" kit you see on infomercials, but that's been with intact screws where the recess has stripped (usually hex)

I don't use the drill portion as I find it usually makes it too smooth for the puller portion to bite.

For what you have, I've never had anything work short of just drilling it out. I start small, using a punch to dimple the end for a starting point. once you get the small bit deep into it you can start working your way up. When you get close to the actual diameter of the threads stop and try to force a screwdriver of some sort into the hole you've made and turn it out. Usually this is how I've got them out. Worst case is you drill it all the way out and have to chase it or re-tap it.

I've got a better idea. Just drill out to lets say 5/16", go to the parts store a buy a pack of 5/16" "christmas tree" fasteners. Done

UPDATE: I bought one of these:



IRWIN Hanson Ex-2 Screw Extractor and 7/64 In Bit Combo
https://www.lowes.com/pd/IRWIN...Bit-Combo/1000363537

It's more tapered and goes in farther, but it just spins. So I drilled the hole a little deeper....
It goes in about half way down the threads of the extractor but it doesn't "bite" on the metal. It just spins.

Which is why I recommended against this type of extractor in my previous post. These also tend to break off in the work more frequently, greatly complicating your problem.

It's very important that you use the correct drill bit for the size and type of extractor. The EX-2 in the picture above, for example, requires a 7/16 drill bit. If the bit isn't biting, you need to drill deeper.

Irwin also makes the same type extractor I previously pictured; those can be set with a hammer or drift (lightly), assuming the hole is deep enough and the correct diameter, and used with a socket. There's less likelihood of getting an angle on the hold with the extractor and breaking off the extractor. You're able to bear down a bit more during extraction, which is important. The extractor isn't as long and thin, meaning less chance of breakage.

You can also use a bit of valve grinding compound to increase the friction between the extractor and hole edges.

quote:

Which is why I recommended against this type of extractor in my previous post. These also tend to break off in the work more frequently, greatly complicating your problem.

Yes... but the IRWIN Hanson Ex-2 was handy at the hardware store and I didn't see anything like that... so I thought I would give it a try.

quote:

Those particular ones are from Home Depot, made by Lisle, but there are several versions, and Napa usually has them.

They didn't have them.
But it looks like I can order them and then pick them up when they come to my local store.

Lisle Stripped Screw Extractor Set (10-Piece)
https://www.homedepot.com/p/Li...0_D_BwE&gclsrc=aw.ds

This style is hands down the best.
I'm a retired toolmaker and I've had the pleasure of removing many broken screws and bolts.
The spiral ones almost always break or you can't get a good bite on the broken screw.
Just my 2 cents.