Try using a CCW 5/16" drill bit...SLOWLY! It'll probably catch on the 'burred up' edges of the Torx and will back right out.

 

Another suggestion might be to use one of those hammer driven impacts. One tap with the hammer and it should knock it loose.

 

The screw was in pretty tight. Since I needed to replace it anyway, I decided to drill off the head. I used a 9/32" drill bit. It took no time and solved the problem. Once the derby cover was off, I unscrewed it by hand.
Thanks for all of your input.

 

impact driver is the answer, one tap and they come right out.


http://search.harborfreight.com/cpis...iver&Submit=Go

 

I think with a drill there's at least a small chance the bit will slip and mung-up the derby cover. With the chisel idea there is little chance of this happening. As someone mentioned, a punch should work fine in lieu of a chisel.

 

Buy better tools!!

 

If the torx is stripped you already have a nice big pilot hole to guide your drill bit. It's not going to just jump out.
You get to use both hands on one tool to safely guide the drill home. Takes a second to drill the top off the screw.

With an impact driver you're using two tools and one of them is a Hammer! And you're swinging it directly at your aluminum primary while holding another tool.

With a chisel and hammer....same thing kinda. A chisel or punch will take a nice chunk out of the chrome of your primary if you happen to miss.

The only time I ever use a punch and hammer is when you cannot get to the front of the screw (like close quarters)...otherwise the drill everytime...

No offense to anyone the prefers the other methods. Guess I'm just good with a Drill or shoot maybe I'm just afraid of hammers?

lp

 

It's the screw on the bottom right isn't it? Ask me how I know. I have a brand new torx bit I ONLY use to break the screws loose, I've got an older used one I use for taking them out and putting them back in.

 

When you get that POS torx bolt out........do yourself a favor and get some chrome socket head bolts.

 

I guess I've been lucky. Here's what I use: