Broken allen wrench in set screw

[NoBanStan]

So I tried to remove a set screw recently. It's 3/32 and i gave it maybe 5lbs of pressure and the allen wrench snapped off in the set screw (thanks wheelers). Now i can't remove it. Any thoughts or ideas on how to extract?

[RED333]

Powerful magnet; I have a few magnetron magnets and a fishing magnet. Works well  for just the same issue as you have.

Edited February 27, 2023 by RED333
Because I can

[NoBanStan]

4 minutes ago, RED333 said:

Powerful magnet; I have a few magnetron magnets and a fishing magnet. Works well  for just the same issue as you have.

I bought some magnets, but the issue is that the set screw is recessed. Very tiny hole. I may try to buy something smaller/strong, but i worry that with the torsion of twisting the allen key... it may not come out cleanly.

[RED333]

What about acceleration with a Sudden stop?Get a rubber mallet, hold the part in your hand with the setscrew, pointing at you, strike it aggressively with the rubber mallet and see if that jars the broken piece loose.

[NoBanStan]

2 minutes ago, RED333 said:

What about acceleration with a Sudden stop?Get a rubber mallet, hold the part in your hand with the setscrew, pointing at you, strike it aggressively with the rubber mallet and see if that jars the broken piece loose.

worth a try for sure.

[RED333]

If you take a pic and pick at it, will it wiggle it all or is it stuck good?

[NoBanStan]

36 minutes ago, RED333 said:

If you take a pic and pick at it, will it wiggle it all or is it stuck good?

immovable. i can probably snap some pics later. just working for the moment.

[derf]

Give us a picture of what you’re working with. Lots of good ideas so far. 

[Grayfox54]

More than likely the piece has deformed and gotten itself jammed in the hole.  

Another hammer method. Hold the piece upside down over the work bench. Lightly and repeatedly tap it with a light hammer. The idea is to set up a vibration that will shake the piece loose. 

If that doesn't work, take a small pin punch and working at the outer edge, lightly tap the piece in the opposite direction trying to work it loose. 

Above all, be patient, go easy and take your time. 

[NoBanStan]

That's about the best quality i can get with a camera phone. I've been digging at it to try and free it up. seems the metal is quite flimsy, but it just won't budge.

[Wheelgunner]

Could you use a strong bit (masonry bit maybe) and bore out the broken wrench piece?  If you could even just bore a good way into it, you might be able to lever it out with an awl.

[sbeck37923]

If you can, try a left handed drill bit about the size of the broken hex key.  Put it a drill and run it very slow in a unscrewing direction.

If it was put in with lock-tite, you may need to apply heat if this will not destroy your part.

 

[NoBanStan]

6 minutes ago, Wheelgunner said:

Could you use a strong bit (masonry bit maybe) and bore out the broken wrench piece?  If you could even just bore a good way into it, you might be able to lever it out with an awl.

this seems like the most likely method at this point.

[NoBanStan]

1 minute ago, sbeck37923 said:

If you can, try a left handed drill bit about the size of the broken hex key.  Put it a drill and run it very slow in a unscrewing direction.

If it was put in with lock-tite, you may need to apply heat if this will not destroy your part.

 

@BigKhad made the suggestion of sticking a soldering pin down in there to heat it up. It's all metal until you get to the polymer receiver. So that might work.  Maybe i'll drill the wrench, heat it up and then try reversing it.

[papa61]

pin vise and miniature drill bit. they make very small drill and extractor pairs. I can't remember where I got mine but most likely from a hobby shop.

 

[BigK]

Do you think a couple good whacks w/ a hammer might get a  flat tip screwdriver to wedge into the set screw enough to twist it out?

[hipower]

3 hours ago, BigK said:

Do you think a couple good whacks w/ a hammer might get a  flat tip screwdriver to wedge into the set screw enough to twist it out?

I did it this way once, but it wasn't on a firearm part. Took some tiny cheap screwdrivers and checked till I found one just bigger than the space on the break. 

I beat the heck out of it actually, but got it out. I was working with an old hazmat cabinet that I rescued from a dumpster. Got one good one that needed a new back on it, and one that looked like it had been run over with a tank.

I'm Cheap! Wasn't going to let it get away from me. Been a dumpster diver most of my life.

Edited February 28, 2023 by hipower

[peejman]

Lots of good ideas. I'll add trying a spring loaded center punch.  That plus some penetrating oil might help pop that tip loose. 

[Hozzie]

I would use a small dowel and some super glue

 

[tacops]

small drill bit to drill small pilot hole then use very small coarse thread screw or tap to get a thread bite and pull.

[RED333]

8 hours ago, Hozzie said:

I would use a small dowel and some super glue

 

This is a good idear.

[derf]

Ok. Take this to a machine shop. Any machinist worth his salt can have this out and not cost you too much. You’re killing me, you gotta get this out. 

[NoBanStan]

I appreciate everyone coming to my aid. It'll be this weekend before I have the bandwidth to focus on it. Will post the results then.

[DocHawk]

Gunsmith here. Left hand extractor with heat.

[Grayfox54]

Don't worry about the broken Allen wrench. Very likely that set screw has lock-tite on it. Apply some heat (not too much) and try to remove the entire set screw. Good methods have already been mentioned. 

Edited March 2, 2023 by Grayfox54