Steel screw broken off in aluminium throttle body

[Christ]

Originally Posted by RobertSmalls

I ground it flat with a dremel, then tried to center-punch it with a nail. Not a chance. It blunted my best nails.

That's the point when I gave up, and replaced the throttle body as a unit. I was avoiding that because I didn't want to break the throttle cable adjustment screw. No worries there, because that screw is brass.

Job's done, Insight's got an IACV now.

I had to steal screws off my bicycle because I didn't have any other M5x0.9 bolts that were long enough.

Well, now would be the time to work on it on a bench or table and get it out of there, so you have a spare, eh? (Or a piece to sell.)

A good, sharp center punch will make a dimple in even hardened steel.

[NiHaoMike]

If you have a high current DC power supply (an old PC power supply should work) and a large inductor, you could try setting it up such that the magnetic field of the inductor pulls the nail away from the workpiece, breaking the circuit and drawing a small arc, then springing back to complete the circuit again, thereby making a crude mini plasma cutter.