Hi Michael you just beat me to it silver steel for me loads of sizes easy to work and harden as you say

I think you've got your solution provided you've got access to a lathe!

I was going to add if/once you make this cutter, you could carefully drop a bit of super glue onto a small spring and drop it inside the mouth of the cutter and that way when you reach the end of the cut the spring will ease/eject the waste plug from the center too. Alternatively, you could drill a small hole from the other side that will allow you to poke it out with an appropriately sized pin/rod.

Michael W

Edited By Michael Walters on 30/03/2016 13:54:40

I have used roll-pins, but agree they have rather thick walls

For something more subtle: Hypodermic tubing looks the obvious choice

**LINK**

MichaelG.

Bugbear, you say you are thinking of using roll pins and also say filing a few teeth is not rocket science but you will finf the spring steel used for the pins is hardened, bit like trying to sharpen a hardpoint saw!

The reasons we have suggested the right material is that it can be worked and then made to keep an edge rather than use something that can't be worked and that will take the edge off your file.

Any K&S stockists should have tubes that telescope inside each other, won't be as durable as a hardened tool but will be close on size and the next size up will make the plug for the extractor below it

Edited By JasonB on 30/03/2016 16:28:01

I though hypodermic needles might do the job so I googled "hypodermic needle sizes" and found this link and this link
The 7 or 6 gauge look about the right but I don't know where to suggest to buy them. The only think I can think of is to see if you could get one from a vet that deals with large animals.

Les.

using a small soldering iron to heat up the screw normally loosens it enough for easy removal via a lh drill or if any part is proud by gripping with small pliers or side cutter

“Both the screws I have to remove broke off inside the hole”
few screws are smaller than 1/16th inch – the tip about 1 inch long of my smallest iron is 1/16th so your screw would have to break a long way down – Maplin/B+Q etc sell “el cheapo” dremel-like (tho not as good) drills often at around ?20.

what size screw are you trying to remove?

root dia of a #3 is 1/16 + shank 7/64th – suspect my iron bit would fit – obviously depends on how much of screw is left – suspect even a drop of epoxy on end of a 1/16 rod would give sufficient grip to extract after heat treatment to break any lock on thread