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It looks like there was a broken aluminum screw that broke and someone tried to remove. Unfortunately it looks like someone tried to drill it out but the screw is partially there. For the hole i was thinking a out trying a 4-40 heat insert but wanted to see if anyone had any tips on removing the partial screw? Picture attached of the hole.

Is it accessible from inside the case?

If the hole passes through, you might be able to somehow get the screw out that way.

If it's an aluminum screw it will be soft, I'd drill it up the center with a pin vise or drill press if you can make a solid enough jig for accuracy. Then I'd attempt the smallest easy out which is a #1 I believe, failing that I would grind my own easy out tool.

May sound crazy but have you thought of gallium it's a metal that eats aluminium , look it up on YouTube, if you could get it in the hole it would be a non mechanical method of removal .

You could try a left handed drill. A left hand drill will unwind the screw once it starts to cut. I have used LH drills sucessfully in the past.

A left hand twist drill bit would be the equivalent of is a regular right hand drill bit and an easy out. The problem with any drilling is that you will need to stay on center with the drill bit. If your drill bit walks to the side and touches the plastic, it will then walk all the way off the screw and only drill the softer plastic. Making a center dimple in the screw to get the bit started drilling in the center is important. Also using a really small drill bit (smaller than screw diameter) is also important to make sure only the screw is being drilled.

Original formula Simple Green is said to eat aluminum too. I haven't tried doing that so no idea how slow that would be.

Thanks for the tips guys. I am going to see if i can left hand drill it but am going to try center punching it. The gallium trick sounds cool i may have to look into it.

Dadio wrote: ↑Sun Mar 26, 2023 1:18 pm

Wow! I wonder if it would cause any issues with residue if I put a steel screw back into the hole after? There must be some sort of neutralizer that can be put on it after.

fleetwood472 wrote: ↑Sun Mar 26, 2023 1:26 pm

Dadio wrote: ↑Sun Mar 26, 2023 1:18 pm

Wow! I wonder if it would cause any issues with residue if I put a steel screw back into the hole after? There must be some sort of neutralizer that can be put on it after.

Far as I know it's only ally that gets eaten, it's on the no fly list, illegal to take on any airline flight.