Electrical box

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wrote:

Just a follow up ... tried a drill bit, just couldn't get a grip to push it through. As originally posted, I made more of it than needed. Had to get some corrosion off the back of the screw and then used needle-nose on the back-end of the screw to move it a little, a little more and finally got it out (a quarter turn at a time).
I appreciate all of the replies and ideas. Hopefully it'll help others too.
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I drilled two today. It's a 6/32 screw with not much to drill into. I have a bunch of tiny drill bits and slowly work up to a #36 or 7/64". Sometimes the broken piece will loosen and fall out as you're drilling. Sometimes the drill bit will break. Have a 6/32 tap and an 8/32 tap handy in case you need to make the hole bigger. It's a slow process, but worth it if it keeps you from having to repair the wall. Mine were embedded in brick.
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The screw in question is to mount the outlet to the box, so drilling out the screw and replacing it with a larger screw is invisible as long as the replacement screw does not have so big a head that the coverplate will not go flush to the wall. I would drill it out with any reasonable-sized drill bit, find a sheet metal screw that will secure the outlet, and put the cover plate on. 5 minutes maximum as long as you have an electric drill of some type and some small drill bits.
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