Stuck Screw Removal

JSDSKI · 01-23-2005, 03:08 PM

It's a steel screw stuck (hell, bonded or welded is more like it - from electrolysis?) in the tab of a front '72 lighthousing that is made of some kind of potmetal. Probably been there for 30+ years. I've tried penetrants and I'm about to try heat but I'm worried the potmetal piece will bubble away in flame!

Any tricks ?

rexav8r · 01-23-2005, 03:21 PM

Depending on the size of the screw, of course...

You can use a dremel (or drill) to drill a hole (must have a strong bit) as close to the center as possible.

Then use an "extractor" bit the same size as the hole you drilled & wrench to get it out.

I've had to do this a few times before...

Good luck!

afterburn 549 · 01-23-2005, 04:06 PM

if nothing else drill off the head and pull the part off...you might have more shank to work with.....or impact screw driver..or heat cycle a few times with your favorit flaver of penitrate and then whack it a couple of times then the impact

john walker's workshop · 01-23-2005, 06:06 PM

the afterburn method works well.

thastings · 01-24-2005, 04:35 AM

Try one of those Sears Craftsman extracter sets that Bob Vila is advertising on the TV. They really bite into the head of the screw and can be used with a drill, in a hand screwdiver with interchangable tips, wrench etc.
Is this the big headed screw on the bottom lip? I need one of these for my '72T and can not find them in the host's catalog. My right one is being held in place by the tight fit only.
Terry Hastings

JSDSKI · 01-24-2005, 07:06 AM

Thanks guys. The problem is the "connection" between the two materials - it really seems as if the screw and housing tab are just fused together. I took it to a machine shop thinking they'd have the right bits, extracter, etc - but they said they'd never get the bit to stay on the screw. I was hoping some kind of chemical solution would break the screw free. Guess I'll break out the fire-wrench....

Porsche_monkey · 01-24-2005, 07:40 AM

If you have a welder, run stick weld current through it.

john walker's workshop · 01-24-2005, 08:45 AM

drill the head off. wedge a screwdriver under the head to keep it from turning while you drill. the caged nut behind it is loose in it's cage.

jpnovak · 01-24-2005, 08:58 AM

Is the problem the front Turn signal bucket? If so the screws insert into speed nut type clips on the fender. You can cut them from the rear and pull the light housing out. Then grind the bolt flush and drill from teh back side starting with small bits and working up. it would be easier if you could pull the fender to get to it. I think the battery box may be in they way to cut the front screw. you could probably get to the back one.