Dunno, but can't you just use a drill extension? You can get either rigid or flexible extensions with a magnetic hex socket at one end and a hex 'plug' at the other. I haven't yet found a circumstance where one or the other won't fit.

Basically, a toaster has stopped working and the tamper proof hex screws are both very small and around 25mm deep. So anything with an extension will not go in the hole. My longer reach torx fit but it is not a torx head.

I had to take a photo with a boroscope to see the head as it is virtually impossible to see by eye. Of course, it is just a cheap, probably Chinese made toaster, but it is probably nothing more than some crumbs that need cleaning out and I am opposed to buying another if that is the simple fix.

3mm may just about work, 5 will certainly be too large. Given that it is possible to buy all the torx sizes, I don't understand why similar hex security long reach are so rare.

Peter, I agree with you but how 'tamper proof' does a toaster need to be?

I know we live in a disposable society and desperately need to boost the poverty stricken Chinese economy, but if I can do a simple fix, then I will.

Of greater interest, why is are long reach torx so readily available but tamper proof hex (Allen Plus?) not?

If you possess a set of screw/ broken bolt extractors - left hand tapered thread, it might give enough grip to get the thing out.

You could tap one of your existing longer Torx bits into the hole and hope it grips well enough to unscrew it.

Find a piece of thin wall tube and form a hex on the end.

Should provide a couple of hours entertainment anyhow

Drill a hole in an Allen key?

In the past, I've welded one onto the end of an old screwdriver and turned it down. Need a welder and some kind of grinder for that though.


Alternatively, if you have a Dremel, you may be able to grind away the "nipple" in the screws that forms the security part. Using a small diamond bit. But that'll be very tricky to do in the confines of a small, deep hole.

Another alternative option is to, if the sizes are close, enlarge the hole slightly, so there is clearance for the extension. However, the plastic will probably be pretty thin so won't take much thinning.

Unless you have a lathe and carbide or diamond bits, forget drilling a hole in an Allen key. Though, if you had a dremeltype tool a steady hand and appropriate diamond bit, you might be able to make something workable with that.

Drilling into an Allen key; don't have a lathe. Don't have a welder either.

May consider buying a cheap set of long reach torx and grinding the stars off which is probably the easiest way forward.

Years ago, did consider a Duralit but SWMBO has to approve and she is not a Duralit style fan. Also, years ago, had a Kitchen Aid toaster which was excellent, until the heating wire broke. Not only almost impossible to get inside the thing but the cost of a new element with the wires wrapped around was about the same as buying a whole new toaster.

So these days, we tend to go for the least expensive, knowing that it will become rubbish in a few years time.

As I said above, have to support the Chinese economy!

Hate throwing stuff away without having a go at fixing. Pet hate is microwave interiors that are now painted and not stainless like the first ones were.

Think Wills idea of testing what the issue is without taking apart is a good one and gluing after butchering the screw is sounds good. Can you not jamm a flat head thin screw driver/terminal driver in with the help of a hammer ? Maybe with a blob of epoxy on the end if not a snug fit.

Left handed/opposite direction drill would likely get the screw out and be useful for repairing other stuff if you can get one long enough.