Topic: How to get this out?

[stereosilence]

I have this screw stuck under my alternator cover. I tried to get it out, then dremeled a slot and stripped that, then tried a screw extractor and it was too big (I think) and broke the head off. Any good ideas? I don't have a welder. Is my only option to try to get the smallest extractor I can and do that?

If Honda engineers were so smart, why did they think it was a good idea to use philips head screws?

[lucky]

I have this screw stuck under my alternator cover. I tried to get it out, then dremeled a slot and stripped that, then tried a screw extractor and it was too big (I think) and broke the head off. Any good ideas? I don't have a welder. Is my only option to try to get the smallest extractor I can and do that?

If Honda engineers were so smart, why did they think it was a good idea to use philips head screws?

The phillips screws were a improvement over what we had.
A slot head screw was very frustrating to remove because the screw driver would not stay centered. A phillips screw driver would stay centered.
Also the single slot screw drivers came to a tapered wedge shape and did not fit into the slot properly like the earlier old time screw drivers.
The phillips screws are not a problem if the correct size phillips bit is used and an impact driver is used to loosen them.
Sometimes just a simple tap on the screw with a small ball peen hammer before loosening is all it takes.

[Old Scrambler]

Several methods......drill with tiny tap.....then heat the case and freeze the broken cap-screw.  Take it to a welder.  File two flat-spots on each side of the screw and turn it loose with a small open-wrench.  Soak in penetrating fluid, cut a vertical slot near the base, then tap with a sharp tool to loosen. Try them all.......have fun.