There are screw extractors you could use, a hollow tube with sawteeth.
Place in drill, over top of screw and drill to depth of screw. Remove
plug with screw and glue in a dowel.Any hardware store should carry
Another option is to leave the screw in if it is below the mortice.
Then drill for another screw to go thru it.Use wax and predrill holes
From a hobby shop get a piece of brass tubing with an inside diameter
large enough to fit over the screw. Cut a piece about 3-4" long.
With a small file, cut some 'teeth' in the end of the tubing. Chuck
this in a drill and drill down over the screw. This will leave you
with a plug which has the screw inside it. Bust that plug out, and
the screw with it. Now replace the plug with a piece of dowel and
some glue. When it's dry, drill a pilot hole and replace your screw.
Sears sells some nifty screw extractors. They work well.
Some more information might also be helpful. What kind of hinge, what kind
of screw? what size of screw?
If this is a door hinge, you might be able to drill the head off the
offending screw, remove the hinge and grab the stub of the screw with a
small pair of vise grips.
About the time I had mastered getting the toothpaste back in the tube, then
to drill a small hole on two sides of the offending screw. You can then
get the pliers on it and rock it back and forth to help get it out.
Then drill a larger hole, put in a piece of dowel, sand, goop with
*spackle*, and bake at 350dF for 1 hour.
Thanks all for your help - Whoever suggested the sharpened piece of copper
tubing chucked in the drill - worked like a charm! I started the hole with
a 3/8 fostner, chucked a piece of 3/8 sharpened copper tubing and drilled
into white oak like butter. Used a 3/8 plug cutter and the glue is setting
Thanks VERY MUCH! ...I was really stressing about it!
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