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I had a tip stick like you describe once. Drilled out the bulk of the screw, but the tip was stuck fast.
I used PB Blaster down the passage, and several cycles of heat, using a torch. Not stupid hot, but enough to boil the oil. I also put a punch down the hole, trying to kick the tip sideways, breaking it free. I was almost ready to give up, when all of a sudden, the broken tip just fell out.
BTW, the best way I've found to remove stripped pilot screws is to drill a small hole in the tip, and then pound a torx bit into the hole. That usually affords enough leverage to get it out. Of course, use plenty of penetrating oil and heat first. That's a given.
I used PB Blaster down the passage, and several cycles of heat, using a torch. Not stupid hot, but enough to boil the oil. I also put a punch down the hole, trying to kick the tip sideways, breaking it free. I was almost ready to give up, when all of a sudden, the broken tip just fell out.
BTW, the best way I've found to remove stripped pilot screws is to drill a small hole in the tip, and then pound a torx bit into the hole. That usually affords enough leverage to get it out. Of course, use plenty of penetrating oil and heat first. That's a given.
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