while attempting to replace my 65mm bracket for an 80mm one, I stripped a couple of the screws in the Z-slider. I was using the correct 2.5mm hex but the screws are soooo tight. It stripped any way.
Any ideas on how to remove these? they are in there really tight and having i am not sure the normal tricks for screws will work but willing to try any thing right now
A picture would help of the problem, but generally if you strip out a thread you have 2 options. 1. Redrill the hole to the next size up and cut a new thread with an appropriate tap
2. Use a helicoil repair kit (though I’ve never used one on aluminum to be honest.)
Secondly, I’d check the hole and screw with a thread gauge. It’s possible they are not the same.(Ask me how I know)
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Not sure what damage you have now, but experience indicates that the allen key needs to be given a sharp snap to loosen the screws, not brute force but a quick snap of the wrist. Tightening, turn the screw in until you hear/feel it click, If 5mm or larger I usually give it a second click. It is all about the feel.
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I have ground a straight slot in screws with stripped drive heads before. Then used a flathead screwdriver to turn it.
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If the head protrudes above the surface I do something similar and grind the sides so I can get a wrench across the flats. I get more leverage than a slotted screwdriver.
I’ve had good results with left turning drill bits and twist in extractors. Several times the drilling slone has removed the screw remnant. And if they are still in there tight, you may be able to just chase the threads with the same size tap to clean them up.
On next go round, follow the prior advice. Turn slow til it clicks (then back a quarter turn 
)
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