@ my wits end

[SJ13]

I have encountered an inset screw{allen head} that I can't seem to conquer it is rounded and the said wrench won't budge it I've tried filing down the corners a bit to try and get it to fit further down inside I also filed down a flat screwdriver to fit down inside also but had no luck with either, since this is an inset screw on the chromed mirror I am hesitant of drilling it, any suggestions from you Guru's out there would be greatly appreciated

[SSsssteamer]

Use a left hand drill bit with a left hand direction electric drill. Use cutting oil and a slow speed as the allen head is hardened. If it doesn't come out with the left hand drill bit after breaking out through the bottom, then use an easy out on what is left. If all of that fails, then drill out what is left with a clearance drill for the size of allen head screw that was used. After that, with a scribe , pick out what is left of the old set screw threads. The success of this is dependent on how hard the allen head set screw is.

[rick55]

If you have a rotary tool such as a Dremel you may be able to cut a slot deep enough to use a screwdriver. I have never had much luck drilling Allen head cap screws due to their hardness but a lot of stuff out of China these days has them as a suggestion of quality and they are as soft as butter. You can actually strip them while you are assembling sometimes.

[smtichy]

I recently conquered one of these, it was a brass bolt (lawn furniture) it still had some part of the hexagonal corners intact so I was able to insert a snug fitting Torx driver (with the help of a hammer) into it. It got it out.

[Ole Don]

When you put it together again, use liberal amounts of anti seize. Its dirty icky stuff to deal with. But if you keep the car, you will be happy you used it, and if you sell the car, the next guy will thank you. I use the Permatex brand, and for some things I use motor oil mixed 50/50 with STP.

[jsprengeler]

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Don't forget "generous amounts of preferred alcocoholic intake" on the part of the mechanic involved.....

[Ole Don]

Alcoholic beverages seem to make for sticky tools, smeared with blood. I just hate that.

[rick55]

The alcohol also makes for blurred vision and a sore head from forgetting to duck whilst walking under the four post hoist. Geez I hate that!

[Diavolo]

There are a couple of options I have used with great success. I usually attack this problem in this order.

1. Spray deep creep all over it and leave it overnight if I can.
2. Use a Torx bit that will barely fit the hole. Torx are slightly tapered and will interference fit a loose allen hole. If you can, tapping the bit into the hole to "make it fit" will also help to loosen the rust that's holding the screw in as well.

if that doesn't work and/or it strips it out, then

3. Use a screw extractor like the brand name "Speed out" I have a HF set. I prefer the swirly end that looks like a cone. So far I've not had to go farther than that, but the next step would be to drill it through to get it out.

[SJ13]

Success @ last I finally got the mirror off the car and got it taken apart ... new dilemma has arisen tried heat gun and also baking in oven @ 250 for a few hours in hopes of simply dropping out or with minimal prying ... trying to remove because roller ball for adjustments is worn and mirror flops was in hopes in getting it out and tuning it up ... hints or tips accepted