Screw removal using extractor bits ?

[Greg Cothern]

Try the heat application with penetrating oil.  DO this a few times and let it sit for a few days.  Seen this do wonders in the past.
HOWEVER as you already know aluminum threads wont hold up to much, good luck and if I can help in anyway dont hesitate...

[Curtis_Valk]

Try investing in some left hand twist drill bits for this job. Use a good center punch to get things started in the right area.

I have been surprised by the fasteners that have simply twisted out of a frozen hole once the internal pressure is released by some drilling and subsequent heat generated by the drilling process.

Dave, that has been my experience with LH drill bits as well.  While drilling should be a last resort, I wholehartedly agree you should get some left hand bits for the best chance of success.  Sometimes the screw will back out before the bit has a chance to wander and screw up threads.

Curtis

[Cannon]

Maybe better to ruin the cast sidecover plate than to try drilling with the risk of damaging the crankcase? Check ebay for sidecovers.

[Jester]

I saw this screw remover on an infomercial.  It was really inexpensive and looked like it might work fairly well.  I'll write down the web address next time i see it

here it is 


http://www.asseenontvguys.com/index.asp?PageAction=VIEWPROD&ProdID=380

[Smoked U]

I saw this screw remover on an infomercial.  It was really inexpensive and looked like it might work fairly well.  I'll write down the web address next time i see it

here it is 


http://www.asseenontvguys.com/index.asp?PageAction=VIEWPROD&ProdID=380

Silly Grabbit, stripped fasteners are for Harleys.

[TLRam1]

In case you need a spare motor.

http://dallas.craigslist.org/ndf/mcy/978434666.html

[Jester]

Silly Grabbit, stripped fasteners are for Harleys.