How would you guys go about removing this broken screw?

[FatTuna]

Use a heat gun if you have one. Much safer..

Thanks Handi, I have one in the basement somewhere that I use for making rod holders.

[bluefish69]

Hey guys, thanks for all the replies. You all gave me some great ideas. First, I'm going to try torching it with a cigar lighter and twisting it with the needle nose Vice-grips. If that does not work and it breaks part of the screw, I'm going to try cutting a notch in and twisting it out with the screwdriver. If that fails I'll try the easy out bit. When all else fails I will drill it out and rethread the hole.

Tarfu how do you create the new threads.

Daron, yeah it's a 4th gen SS. I will just end up buying a new one if I can't fix it.

VW used to have 5-40 taps at a great price. 4-40 is common size & can be bought at Hardware store or Home De Pot

Mike

[fsrmn]

 I would use a 50-50 mix of ATF and acetone as a penetrant, tap it with a small hammer, then use the needle nose pliers suggested by Fred.

[jonnou]

Im serious about the side cutters I do this every other day
the key is to cut into the side of the screw for purchase
Needle nose work but have a tendency to roll the screw out of them
its a bit of a trick though
I have been able to remove breakoffs with about 1mm on a 6g screw
good luck Jon

[fsrmn]

You are right Jon. Side cutters or diagonal cutters would tend to grab the screw closer to the base than vice grips and would be less likely to round it off.