So, I have a leaky faucet and I'm attempting to change out the cartridge. I've done this a handful of times so I know it's usually easy. I go to unscrew the set screw that holds the handle on and it's stripped. Ok, let's check the internet for ideas to get it out. I tried the rubber band on a flat head screw, no luck. My spiral screw extractor set (easy out?) has one too small and one too big, so I tried to lightly hammer a "star" screwdriver into the hole, no luck.

So I decide to drill a smaller hole in the hex head to try the small spiral screw extractor on it. It looks like it's gonna work, it grabbed the inside of the new hole and I started to turn it and the easy out and it breaks off in the hex head. What the hell?!?!

I'm stumped, what should I try now? The hex head is sunk into the handle so I can't cut a strip in it to use a flat head to unscrew. Any ideas would be great appreciated…

Could you JB weld something in there that you could grab into? Either to finish the removal or remove the small extractor?

Can you post a pic of the situation?

I've nearly completely stopped using easy outs. They are hard, but they are also brittle. Your experience is not foreign to me. I work on a lot of rusty crap, so, I am happy to toss out ideas, but I need to see the particular setup we are working with here.

If you have a 'head' on it, then you might be able to use a small set of needle nose like vice grips. It will destroy the set screw, and it will mar the finish on the handle if you don't protect that, so be aware.

I had this happen this year. I ended up just using progressively larger drill bits until I drilled out the screw entirely. Wrecked the handle though and had to buy a new one. PITA.

Would trying to drill with left hand drill bits be an option?

Many times the bolt comes out before the entire hole is drilled.

Hit harbor freight or hd or lowes up and get a screw removal kit. Its just handy to have around always in your tool chest.

Example
https://www.homedepot.com/p/RYOBI-Spiral-Screw-Extractor-Set-5-Piece-A96SE51/205469301

Here's a pic of what I'm dealing with. I took off the end of the handle, so that's why it looks funky. I can't drill out more because the end of the "easy out" is broken off inside it. I tried, but I guess those are so hard that the bit won't cut into it.

https://drive.google.com/file/d/1tYN4ty4Ma1--JhlqdnaEBlPRWLDgCm8j/view?usp=drivesdk

Just my $.02. But you may be at the point of faucet change as opposed to cartridge change. Hack saw or oscillating tool to cut through, remove and replace.

Yep, looks like a faucet change to me.

Just dealt with this a couple of months ago. Buy fatzilla recommended to take it out. You should be able to find a replacement screw at the hardware aisle where they sell special screws and etc

Soak threads of broken screw with Kroil. Repeat for at least 3 days.
Kroil is amazing.

Then try to drill out with a left hand bit with drill in Reverse.

I've been successful twice with this method.
I bought a set of left hand bits at a local NAPA parts store.

SoulSlaveAG2005 said:

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Just my $.02. But you may be at the point of faucet change as opposed to cartridge change. Hack saw or oscillating tool to cut through, remove and replace.

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OP: what screw were you going to use to insert when you finally did get it out and make a successful cartridge change?

I'm just going to replace the faucet now. I was going to try to find a replacement set screw if I got it out, but that isn't happening now.

Are the $50-60 faucets at Lowe's/Home Depot good enough? The ones we have now don't look to be anything fancy.

I've always had good luck with Moen brand. A little more $, but usually better quality/longevity.

Kohler has been OK as well as Price-Pfister, they just didn't seen to like the hard water we have in the greater San Antonio area.

you can sometimes use a thin rubber band over the end of the allen/hex wrench tip and get it to snug in there enough and grip. Sometimes it works.

CapCity12thMan said:

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you can sometimes use a thin rubber band over the end of the allen/hex wrench tip and get it to snug in there enough and grip. Sometimes it works.

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read the Op