Hubby to the rescue!!
 

I was determined to take the tensioner apart on my 15-91 to give everything a thorough cleaning/shining. The set screw however was determined to stay put. In the end ... I won ... but not without some damage to the screw slot. I was mad. I said some bad words. I tried to source the screw on the net, but the only thing I could find was to purchase an entire face plate for $12.00 plus shipping. I said more bad words summing up the probability of paying $12.00 for a teeny tiny screw.

Hubby said ... no problem ... old trick.

He drilled a small hole in a lump of wood then drilled the screw into it, the wood is now a vise to hold the screw.
Using a slot cutting saw (these things actually exist?), he widened and deepened the slot a smidge, then rasped the top to debur it.

Awesome!!

Kind of nice having an engineer around the house :)

In hindsight, I should have let the engineer remove the screw in the first place!! I have zero strength in my hands.

Now ... need to get hubby to remove the two screws holding the motor housing to the body. I tried, they're tight .. and no way do I want to mess up those babies.

well done! besides, the help it keep us out of other trouble....

I had to laugh at this one. My hubby, also an engineer, has done this around here more than once. He has some pretty good screw removal tricks, too, so I'm sure your hubby will have those other pesky screws out in no time.

You all are so lucky - my DH cannot even change a lightbulb and still can't figure out when our car needs the oil changed even when they write it on that little sticker on the top of the windshield with the mileage on it.

Wish I had your husband here. I took apart a quick release rotary cutter, and can't get it back together.. It flew out of my hands when I was taking it apart, so I didn't see which way things go.. I have looked at the videos, and it still isn't working.. ughh

I don't have an engineer but he is still pretty handy...... figures out ways to fix things that I wouldn't have thought of. And, I'm pretty good at fixing things usually.

Praise the man ........... til he's begging to work on the motor housing for you! :D

When I have any kind of problem like that I call DH. He has the right tools and shows me exactly what he's doing and many times has me do it. He says just in case I get impatient and want it done last week and he isn't around.

snicker ... that's how the screw got damaged in the first place.

ahh ... found a toy for him to keep him out of "other trouble". He finally has his convertible roadster. I figured in the long run, it was cheaper than a mistress and we could both drive her :)

your DH would make a great teacher, esp. if he is willing to show how it's done.