Another option might be to rust out or corrode away the steel set screw using corrosive liquids. Perhaps someone here with a better chemical background than mine might be able to recommend something that is corrosive to steel but not aluminum?
Extracting A 1/4 inch Machine Screw With A Broken Head
- Thread starter Rick D
- Start date
I did that ages ago with a steel stud stuck in an aluminum cylinder head.
I seem to remember that drilling it out and inserting a helicoil or other insert wasn't an option for some reason I have long forgotten.
Alum dissolved in water, then heated a bit. A day later the steel should be mostly gone. the problem is making some type of containment system so that the solution can sit on top of the broken steel bolt.
I have no idea is it would work with stainless steel or if it would severely damage the other materials involved.
There is likely some info out there in internet land, since I learned it from an old timer.
