I picked up an old parking meter at a flea market. I'd like to take it apart. One of the doors flips up on a pin which has an allen head set screw in the center that won't come out. It already had a chunk broken off the side and the allen wrench slips. I can't drill it out.
Any suggestions?
Torch it then an upsidedown can of keyboard cleaner to break it free? Then try the allen key with force applied to one side, like pulling the top of the tool towards you, while you twist it. That might work.
"Flea Market" 
Can you get at it with a hammer and mini chisel/thin drift and try to tap the set screw to loosen it?
What size set screw? if 1/8 head set arc welder for 100 amps, place allen wrench in the rod holder, ground to body, then jam the allen wrench in the screw while it arcs and glows, release the rod holder and quickly turn screw while hot with now melted in wrench.
It's small and there's not much material around it. My arc welder is long gone, but I do have a Mig welder. I'm not sure I can hit the allen wrench and screw without getting the cast piece too.
ez out
In reply to Woody:
An easy out will likely do the trick. One thing I've found to work is torx bits. If you take the right size torx bit that does not fit in the hole, and hammer it in it will cut it's own shape into the hardware. It's a no heat method, and a lot of times the impacts help to break it free. It's important that you use an extension and do your best not to put ANY side load that way it has the maximum holding torque.
fasted58 wrote: ez out
I've never had an EZ Out work for me. I've also broken at least one of them inside the frozen bolt.
You need a milling machine. Fixture the meter on the table, use a stub length drill, feed very slowly to get it started on center, drill it out with successively larger drills.
You ~may~ be able to make it happen w/ a drill press, but the rigidity of a mill will help.
I have access to a Bridgeport Mill so that may be the route that I take.
Take an allen wrench and stick it in the allen head. Take a MIG or TIG and tack it to the allen by sneaking a bead down the wrench until it just licks the edge.
While its still wicked hot... load the allen wrench up a little until it starts to deflect and then give it a sharp rap with a hammer.
I like the EZ-Out idea, but failing that I'd weld a washer to it, then a nut to the washer.
OR, cut a slot in the top if there's enough meat sticking up with a Dremel, then use a screwdriver to back it out.
mikeatrpi wrote: I like the EZ-Out idea, but failing that I'd weld a washer to it, then a nut to the washer.
ahh... the old plug weld ploy w/ a nut ftw, yea I'd try that
Carbide drill?
Fill it with jb weld and stick the Allen key in before it cures?
Long shot, I know.
Okay, I have an EZ-Out. This has been soaking in PB blaster for two days (please spare me the lecture on what's better than PB Blaster. It was handy).
How should I attack this? Should I set up the EZ-Out and then add Mapp Gas? I also have Freeze-Off or whatever it's called. I don't want to damage the cast housing.
The remnants of the set screw are not very deep.
I've had good luck progressively drilling it two or three times with progressively larger drills, weakening the inner structure. For the last drill, I use a left hand drill bit (I have a full set) and it usually snags the remaining part and twists it out.
Carl
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