How to Remove a Damaged Setscrew?

glad you got it. I have been successful getting hex sockets out by using Torx bits. The bits fit snugly in the points of the hex, rather than on the flat as a normal hex key does. I can't say it works for all sizes but there does seem to be a correlation between hex sizes and torx sizes. too many to be random chance.
 
good work, now I gotta get me some left handed drill bits.
 
good work, now I gotta get me some left handed drill bits.

If you don't have a screw extractor set, of the type linked, I highly recommend getting a set. I have never been disappointed with mine. It's amazing to see a #10 x 4 inch deck screw spinning out perfectly. The sets include the special left hand drills so, unless you need a larger selection of diameters, they are great where the short depth is OK. I think all I have are made in USA (vintage) but I don't know if any USA made are available anymore.

McMaster sells 2 sets. At those prices I would expect them to be Made in USA.

 
@Winegrower

I should have been more clear about the 'Made in USA' comments. I see a lot of Chineesium hex bits, and the like, advertised as made of S2 tool steel. That's great material but every one I've tried has been brittle hard and broke without doing significant work. They may be made of S2 but the manufacturer hasn't got the temper figured out. I was projecting my S2 problem onto the cheap import screw extractor sets, but that is just a guess.
 
I just picked up another set of EZ outs / extractors from McMaster Carr . One of my sets disappeared in at work while I was off . I've never met a broken bolt that couldn't be removed .

 
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