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
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.
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
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