Gunsmithing Stripped t10

[timelinex]

So I was attempting to take off my hand guard on my jp to put a thermal sleeve on under neath it. Unfortunately 1 of the 6 screws just wouldn't come off and I tried using penetrating oil. Well I ended up bending 3 t10 bits and ended up really stripping the bolt. I've tried drilling it out a bit and no luck. I tried getting a reverse drill bit however the smaller one is a #1 years still slightly bigger than the screw hole, so I can't use it. I've tried to hammer bits into it but that doesn't work either, I thing the screw is stainless steel, because nothing is going in there.

I've tried to use a dremel but the screw and area is so small that I don't have anything circular that's small enough to get thru and make a slot in the head (without fudging up the hand guard around the screw)

Is it just me or does everyone always encounter a tedious unexpected problem everytime you have to do a 5 minute project... And turns it into a multi day ordeal, breaking of tools and alot of frustration.

The part that's making this impossible is that it's such a small and strong screw. If this was a nice size normal screw, a reverse drill bit or hammering a bigger bit in would fix it up in a jiffy.

Any advice?

 

[remr5]

Drilling it out with a quality sharp drill bit and drill press is the way to go. You may wind up re-tapping the hole but without a pic not sure what else to suggest

 

[MikeeBooshay]

Next time you are confronted with that, stop before you strip it out. Apply heat from a soldering iron direct to the head for a minute or so. Use a Snap-on ( accept no substitute, it is better ) impact driver, give it a couple sharp smacks with a hammer, problem solved.

As far as what you have now, either drill or dremel the head off, remove the hand guard, then drill it out in the Bridgeport or drill press. If you are feeling lucky and have the TIG machine, TIG weld an old bit into the head and try the impact driver. Between the heat and the impact, it will come.

 

[timelinex]

Thanks for all the advice guys...

I ended up torching the area, carefully, for a good amount of time and then spent a good amount of time hammering a bit in... Then I was finally victorious.

It was a really big hassle, but I'm glad to say nothing got damaged other than the screw.