recently broke a 8-32 screw off in an old distributor, steel screw in an aluminum housing.
decided to remove it today.
since there was still some good threads at the opposite end of the hole I made a pilot by center drilling a short 8-32 screw.
clamped the housing in a drill press and drilled the pilot hole
it was centered great, then opened it up to 3mm.
alternating between a bottom and taper tap from the good threads at the bottom it cut a few remnants then the last few turned out intact.
and success
decided to remove it today.
since there was still some good threads at the opposite end of the hole I made a pilot by center drilling a short 8-32 screw.
clamped the housing in a drill press and drilled the pilot hole
it was centered great, then opened it up to 3mm.
alternating between a bottom and taper tap from the good threads at the bottom it cut a few remnants then the last few turned out intact.
and success