Help!!!
 

The set screw in my pinion has a broken hex tip in it. It is already installed on the motor sitting in the Rc-monster motor mount. What can I do?

Is the tip jammed in there? I am guessing it is. I would try to find a good dental pick and use the pointed end to pop the broken piece out. If that does not work you may have to drill it out, but that will be quite difficult with the motor installed...

You could remove the the motor mount and motor as a whole and then try and position it in a drill press. You will need to clamp the pinion in the vice and then use something else to support the motor. I would only drill down a 10th of inch or so at a time then back it out. Also make sure to cover any openings in the motor so shavings and debris from the drilling don't get in there.

Another option would be to take a dremel with a metal cutting blade to the gear. You'd loose the gear with this, but you might have to make the sacrifice...

You could also try heating and/or cooling the pinion. The expansion/contraction may be enough to help you remove the stuck bit. Just be careful not to get the shaft too hot because it could affect the rotor magnet.

This is probably not small enough but it may be worth asking if they have a bit that will fit.

http://www.4grabit.com/Default.asp?bhcp=1

put a small steel peice on it and jb weld, epoxy, CA, or even weld it too it so u only lose a set screw

What would be the down side of trying to take a thin dremel blade and cutting a slit in the top? It could knock the tip out or it will give me a place to put a small screw driver.

Sounds like a good bet, give it a try...

Yeah go for it. I do that with the countersunk chassis screws when the hexes strip.

Use a pinion puller - It puts no force on the rotor...

That may work depending on the type of flat spot on the shaft. Some Neu motors have a flat spot notch as opposed to being flat all the way to the tip...

How hard can it be to shear a grub screw??? :lol:

I had to squeeze it with a pair of visgrips until I got the hex tip to pop out. Nothing else that I had would work. The gap between the motor mount and the set screw was to tight. It worked and all is good!!!! Thanks for the help!!! Now the CRT is up and running.