Get this screw out - I dare you

[MDifficult]

So this is actually a 'mechanic' issue but I suspecting you clever folks in the DIY world might be well equipped to help me solve this one..

I noticed that the airbox lid on my R8 was missing a screw. No worries, I buy a new one from Audi (looks like any other VAG airbag screw but this one has a Torx head because 'supercar' and so is 10X the price).





I attempt to screw the new screw in but.. it won't go. Weird. I remove the lid and am presented with THIS.



Ah.. for some reason the original screw is snapped off in the plastic airbox. I suspect it got wet, rusted and failed when someone tried to open it. Not only that, it's actually recessed in so is below 'flush' with the top of the aperture. So it needs removing.

Here's the things I've tried:

- Adding WD40 (although its metal screwed into plastic so no idea if that's helping)
- Mole grips. Far too big to get into the recess.
- Pliers. Not enough grip, even if I grip with all my grip. Even if I grip the grips with mole grips.
- Needle nose pliers. Bent nose pliers. Not enough grip and they flex.

I've even tried putting the tip of a drill down onto the remnants and tightening up the chuck and trying to unscrew it that way.. but the nose of the drill can only get about 3 or 4mm onto the remnants and there's not enough friction to overcome the torque even on max tightness, so it just spins off (and is wearing away what little metal is left in the process).

At this point.. bar replacing the airbox I'm a bit stumped. I could try to flatten the top and Dremel a groove in the top and use a screwdriver (but I'm very skeptical on that as it's so small and clearly soft). I could weld a tiny nut onto the top (but I don't weld or have a welder). I could drill it out, but I suspect as what it's screwed into is plastic, the drill will use find the plastic and drill through that instead.

So.. clever, clever folk... any ideas? All (half sensible) suggestions welcome!

Thanks

[markiii]

tried needle nose mole grips?

by the way WD40 is crap as release agent, try plusgas

[E63eeeeee...]

Can you get the airbox out and get at it from the bottom?

[timbo999]

https://www.screwfix.com/p/metal-bolt-extractor-se...

[Grey_Area]

Get some heat resistant putty, place it around the rusty screw, using one of those really small lighter torches; heat the rusty bit, then undo with long nose pliers or similar.

[alscar]

Seems an odd place for so much water to have got in to cause rust but irrespective , wedge in the smallest socket possible ( packing it out if not small enough ) and “ hope “ it then turns ?

[MDifficult]

markiii said:

tried needle nose mole grips?

by the way WD40 is crap as release agent, try plusgas

Good idea! I didn't know such a thing existed. Maybe a really, really small set might do the job. There's so little to grab on to though.

E63eeeeee... said:

Can you get the airbox out and get at it from the bottom?

Thanks - I can get the airbox out but no, it's a blind hole that the screw goes into.

timbo999 said:

https://www.screwfix.com/p/metal-bolt-extractor-se...

Cheers but nope. What you're looking at is a 2mm (maybe) diameter top. There's no drilling into it small enough and no extractor small enough.

Grey_Area said:

Get some heat resistant putty, place it around the rusty screw, using one of those really small lighter torches; heat the rusty bit, then undo with long nose pliers or similar.

Thank you - not a bad idea although with quite some risk. As a last resort, I'll definitely think about it!

alscar said:

Seems an odd place for so much water to have got in to cause rust but irrespective , wedge in the smallest socket possible ( packing it out if not small enough ) and hope it then turns ?

One drop of water in that recess and it'll just sit there until it evaporates. That's my guess anyway. No socket that small I'm afraid and nothing for it to grip too - it's the shaft of a screw with the head snapped off, not a hex bolt.

[stemll]

A pair of Vampliers will probably work best in there

[MDifficult]

stemll said:

A pair of Vampliers will probably work best in there

Wow! I'll be honest with you, I've never heard of such a thing but a quick look on Amazon and you know what.. it might be worth a go!

Just need to find a very small set with a narrow nose. A bit like this: https://amzn.eu/d/97I2WZu

They also seem to do them with mole-grip style locks which might be really helpful. Okay, definitely one for me to explore, thank you!

[BlackZeD]

You need something like these, although 1/4' is the smallest.




https://www.amazon.co.uk/18-Piece-Stripped-Remover...

[MDifficult]

BlackZeD said:

You need something like these, although 1/4' is the smallest.




https://www.amazon.co.uk/18-Piece-Stripped-Remover...

You're right, but the smallest I've seen anything like that go is 6mm. I need 2 or 3mm unfortunately.

[jfdi]

stemll said:

A pair of Vampliers will probably work best in there

Another one for the list of tools I didn't know existed but now definitely need

[MDifficult]

I've ordered the two best looking Vamplier options. I'll try them, maybe with a little heat onto the screw (maybe via a soldering iron to reduce the risk) to melt the plastic a smidge and we'll see what happens!

Thanks all

[cookie1600]

Vampliers would be my choice but if there is still any thread on the broken shaft, can you get two nurs on there, lock them together (tight) and then try winding it out with a socket.

A really long shot could be drilling a small hole across the shaft of the broken bolt and using a tiny screwdriver or rod through the hole (maybe with long nose pliers too) and use some Plusgas and grunt to loosen it out.

The last resort would be to grind it all out with a Dremmel then drill and re-tap the stub/casting and put an appropriate new screw back in with grease.

[Mr Whippy]

Hmmm, so it's self-tapping into plastic and is stuck that bad?

Can't you just snip it off, drill it out and remove the remnants?

[OutInTheShed]

Variation on the drill chuck idea, a 'pin chuck' or pin vice of the right size might grip it?
A bit like a dremel collet.
You could try soldering a tube over the shaft of the screw?

If the screw is into 'real' carbon fibre, it could be a corrosion problem, carbon is quite active.

You could use a mini core drill over the shaft of the screw and bore it out, if there is enough 'meat' around the hole to epoxy in an insert for new screw.
https://www.ebay.co.uk/itm/127252495451

If you can get it hot enough, maybe with a soldering iron, you might soften the resin enough to pull it out. Alas this can go wrong resulting in a better bond and glass-hard resin.

[Ritchie335is]

Show us a pic of the other screws. The thing you are all overlooking and is key, is this a self tap type thread into plastic (which I doubt) or, Is it a machine thread into a bonded insert. If the latter, yer screwed, the insert will just spin likely, even if you get a hold of it.

[stemll]

jfdi said:

stemll said:

A pair of Vampliers will probably work best in there

Another one for the list of tools I didn't know existed but now definitely need

I'll just leave this here then......

https://vampiretools.com/product/premium-10-pc-too...

[DonkeyApple]

I'd certainly leave it awash with a release fluid while waiting for the exciting tool delivery.

[Getragdogleg]

Soldering iron, tiny pliers.

Dont worry about it melting you'll be there ages before a soldering iron puts too much heat in that.