Help! Hex head snapped in set screw (gas block)

[AC_DC]

So, I was installing a new gas block on a recent build and I accidentally over-torqued the set screw which resulted in the hex head bit snapping inside the set screw.

I've tried rare earth magnets, gorilla glue, jb weld, and even drilling it out with a hand drill, but I've had zero luck.

Can anyone recommend a local (SF East Bay) gunsmith or machinist that could help?

Thanks!

[Jimrose47]

Picture of it?

[ar15barrels]

EDM is your safest method.
You could also just leave it in there and shoot it for a while and see if the vibration of shooting causes it to fall out.
If not, next method will be a carbide ball endmill to mill out the whole setscrew.

[Jimrose47]

If he has not messed it up to much he could use a small speed out/easy out. I have done it multiple times it takes all of a couple seconds. But I can not tell for sure without seeing it

[Jimrose47]

where you able to drill it out at all or to hard? A gun smith with a drill press could probably do it

[Barbarosa]

Next time (if there is a next time) drill it out with a reverse-twist drill bit. You can order them on Amazon for a buck or two and half the time the screw just backs out while you are drilling. Might be worth a try if you haven't buggered it up too badly.

[ar15barrels]

Next time (if there is a next time) drill it out with a reverse-twist drill bit.
Might be worth a try if you haven't buggered it up too badly.

His problem is the piece of hardened tool steel that he left IN the setscrew.
Regular HSS or Cobalt drill bits won't touch it.

[Pofoo]

Alternate heat and cold?

[RTE]

Square off 2 sides of a washer and tack weld it to the set screw/allen.
The tack weld will stick to remove the allen...Or if it also sticks to the screw, you'll be able to remove the screw with the flat spots in the washer with a standard open end wrench...the heat will help loosen the screw.

[ar15barrels]

Square off 2 sides of a washer and tack weld it to the set screw/allen.
The tack weld will stick to remove the allen...Or if it also sticks to the screw, you'll be able to remove the screw with the flat spots in the washer with a standard open end wrench...the heat will help loosen the screw.

And if the washer also sticks to the gas block?