[Test-Equipment] Difficult Allen Screws

[WA5CAB at cs.com]

Mike,

My experience is that it's the wrench more than the screw the gets rounded.  
Step 0 is to use good quality allen wrenches (Xcelyte, Snap-on, etc.).  And 
don't use one that shows signs of having turned in a screw until you've dressed 
the end.  Be sure the socket in the screw is clear of foreign material all the 
way to the bottom.  Especially rust.  Soak the screw with a penetrating oil 
(not a lubricant). 

If the wrench turns in the screw, dress the end back with a grinder (fine 
grit wheel).  Do it slowly so as not to overheat the wrench.  One reason I prefer 
black-oxide finished wrenches to plated ones is that you can more easily see 
how far you have to grind.  Don't bother with dressing up the burr on the end.

I've never heard of oversize wrenches.

In a message dated 7/14/2004 12:18:52 AM Central Daylight Time, DrD at 2020.com 
writes: 
>        I need some help and or tips on how to remove frozen Allen 
> set-screws like the ones found on equipment knobs.
> 
>          The typical scenario happens when trying to remove a stubborn set 
> screw. The Allen wrench "slips" and rounds the insertion pattern 
> slightly.  Has anyone heard of a slightly oversized set of Allen wrenches 
> (on the order of .001" - .002") or is this the wrong approach?  If they 
> exist, who supplies them?

Robert & Susan Downs - Houston
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