Penetrating oil, drill, and an easy out......

any other tricks?????

 

As a last resort, I have drilled off the head of the screw if I feel there will be enough of the thread exposed to lock a pair of vice grips on to remove it.

Jim

 

Cut a slot in whatever is left using a dremmel and remove with a flat blade screwdriver.

 

I take it you mean screws whose head has been rounded off.
They sell things called screw extractors. They are like a drill bit that has reverse threads and drill down inside the screw to extract it. Never used them so not sure how well they work.

 

I have a set of screw extractors made by Craftsman. I have yet to have them work like they show in their promotional videos. Most of the screws I have tried have had the heads rounded off while the screw threads are rusted in place. The most effective way I have found is to use an oversize bit and drill off the head. Make sure you don't drill to far into it as to damage the surrounding material. Hopefully once it is apart, you can grab the shaft with pliers or vice grips and back it out.

Jim

 

They rarely do work and often end up snapping, causing an ever problem since they are hardened steel and not drillable. Something you can try is a left-handed drill bit if you can find one.

 

If it was phillips head you may still be able to use the manual impact tool and break it loose. Anyone that has a motorcycle or quad should have one of these. They are cheap and are really usefull. I use mine anytime I am going to break any screw or bolt loose from the engine. For me 9 times out of ten it will come loose with it, and without it I never have any luck. I don't know what it is that causes this but it is a pain in the rear. It must be the corrosion that takes place between the aluminum and the metal that the screw is made of. It always helps to use anti-seize when putting things back together too. Of all the tips mentioned the one that seems to work for me is the left handed drill bit, or just an easy out if the screw is big enough. Good luck

 

Drill a hole in the bolt or screw and get a left handed tap. You can get a left handed tap at your local Fastenal. This is the best way I have found to remove old bolts and screws.