Topic: Help removing broken screws from gas tank.

[Magpie]

Hi! Before I make a mess of this I though I better ask for help. There are 3 screws in the bottom of my 1964 Benly tank that have broken off almost flush with the tank. I need to be careful not to damage the surface of the tank so the tap will sit flush and not leak gas. Done that on a 750 tank already dammit. Any words of wisdom and ideas please and thanks.
Cliff.

[Prospect]

Take a smaller diameter drill and drill through the screw.  Then break in the remaining parts inward.  They should just crumple into the tank which you'll have to fish out later. 

[Magpie]

Thanks, I'll try that tonight! Cliff.

[Prospect]

Also, start off by flattening the top of the screw with a dremel otherwise it's very difficult to start drilling. Second, I would drill a pilot guide hole with a 1/4 of the screw diameter drill then about 5/8 of the diameter drill. Then it'll crumble in with little effort.

[Magpie]

Sounds good! Thanks again. Cliff.

[Magpie]

Drilled it out. It didn't crumble but I was able to drill and tap it for the 5 mm screws it needed. It was easier than I thiought. I justed started small and worked my way up in drill size. Thanks for your help!! Cliff.