Stripped Set Screw Head

[horsemel]

My bimini frame has a stripped set screw head, the part the allen wrench fits into.  What is the best way to remove it.  I am thinking about using some 5 minute epoxy on the end of the wrench and hoping that after it sets-up I will be able to remove the screw. Any other ideas?
Mark Mueller

[Gary]

Mark and Melinda,

I doubt the epoxy will hold the torque the Allen wrench provides. I suspect the screw is stainless and the frame aluminum...very difficult to separate after electrolysis. You could drill out the set screws but that will leave you with perhaps another set of problems.

I have experienced this set screw removal problem and have left the frame in one piece and had a canvas shop install canvas and zippers so the whole Bimini as well as the dodger removes from the frame without disturbing any seized set screws. Has worked like a charm over the years on our 1986 C 34.

Gary

[Roc]

I seem to remember special drill bits (Sears Craftman), that you can use to back out stripped bolts.  I think they work by having reverse threads that bite into the item you need to back out as your drill spins in reverse.  I don't know if they come that small, but you can look.

[horsemel]

The screw is not seized due to electrolysis.  I had it loose and it stripped when tightening.  (No I did not give it the extra oomph.)  I wonder if the wrench might be bad.  I have some of the sears tools and have never had good luck with them, but I may have to try that if nobody has a better notion.
Mark Mueller

[Stu Jackson]

Back it out, and put some silicone into the threads, reinsert and relax.  Don't over tighten.

[Mike and Joanne Stimmler]

The removal tool is called an "easy out" and they are usually available in a set of various sizes at sears or most hardware stores.

Mike

[Ken Juul]

since you are going to replace the set screw you don't need to worry about bunging it up any more.  I would use the original allen wrench and a small nail or brad.  Insert the allen wrench, hammer the brad in to jam it and unscrew.  May need to file it down some to get it in.

[Ron Hill]

Mark : Use a screw extractor (Easy Out) to get that set screw with buggered up head - out. 
Then get a new set screw.

[Ken Juul]

Extractors are great!  I have a set.  But 9 times out of 10 the recess isn't deep enough to get a bite, so you end up drilling the set screw anyway.  6 one way, half a dozen the other.  Since you said the problem occurred because you overtightened you know the set screw isn't frozen.  Try the brad/skinny nail, if that doesn't work then off to the store for the easy outs.

[waterdog]

Drill it out.   Get on with your life.     If it's an end fitting, through bolt it or rivet it (stainless).   If it's a sliding jaw that you need to adjust to tension the bimini top, then move up a size and retap as necessary.   Or just buy a new fitting.   No point running around town buying specialized tools to fix a $15 part that is easily replaced.

[horsemel]

I got the job done.  An old guy in the marina suggested using an old wrench, putting it in a vise and hitting the end once with a hammer.  It mushroomed it just enough to grab.  I did not believe this would work, but it did.  I suppose you could mushroom it too much or too little so I probably got lucky.  Anyway all is well that ends well.
Mark Mueller