Trim wire clip screw stripped Need Advice

[Aaronhl]

The head snapped off when I was taking it off, an ez out then snapped and the tip is stuck in the screw, not sure what to do now...I'd like to repair it as close to original as possible unless you guys have a better idea.
Any advice on how to repair it? And any advice on how to remove the the self taping screws on the next one so it doesn't snap?

[SS Minnow]

I would grind, fill, and smooth out that screw and paint over it. Drill and tap a new hole somewhere close to it that works for you.

As far as removing the other bolt, or other problems like this in the future, do you have a set of left hand drill bits? Not sure if you have heard of them, do not want to insult you, but they drill counterclockwise and since I have been using those to remove snapped bolts, I rarely have to use an easy out. The drill bit usually pops them out while I am drilling.

Good luck!!!

[LakeFever]

I’ve used a few methods over the years. Had an old aluminum oem intake that the same thing happened. I used a rotabroach to drill around the snapped and seized stud and then tapped that hole to 1/2” and threaded in a bolt that I had drilled and tapped the center to the size of the stud ( 1/4” iirc ) then zip cut and ground the bolt flush. This stud needed to be in the same location for the carb to fit and seal.

in your case the above advise is easier but I felt like telling a story this am lol

[Aaronhl]

Good advice guys, its one of the few bolts that always strip when I break down the older mercs. I hate the trim clip screws and the lower engine mounts bolts that screw into the mid section because those always snap too...

[Aaronhl]

My drill bits suck maybe they are too dull so when I try to drill out a screw it ends up walking and going into the aluminum. Or if I start with a small bit it will end up snapping in the hole just like the easy out did...

Good news is- I ground out this stripped screw with a fine point dremel bit, making sure to only grind out the steel and not the aluminum. After I grinded fully through, I drilled the hole with a drill bit to clean it up. I am going to thread 10-32 directly into the aluminum so I can use stainless screws to mount the cable clamps...

[Forkin' Crazy]

Spot weld a washer to it and then a nut. ??? It has worked for me.