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Removing de-threaded cleat screw
NB: Originally posted elsewhere on the Global Riders Network and appears via syndication.
So I stupidly dethreaded one of the screws of the cleat with my allen key when trying to unscrew it. I've tried many different allen keys and all of them turn without turning the screw.
Tried to drill a hole thru with different bit sizes, different speeds, even tried hammer mode - seems impossible to drill those screws which are tough to drill in!
Any tips on how to remove the screw please ? Maybe I should try a more powerful drill but then there's the danger of damaging the plates on the shoes 
Tom
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I've had the same thing with my cleat screws. I used the smallest screw extractor that I have (purchase from a hardware store for about the same price as decent drill bit) which meant that I only need to drill a very small hole. You're correct about the drill, my cordless, although a good unit, didn't do the job, I used the corded drill on a low speed with a decent drill bit (cheapy drill bits just blunt too easily). You're right though, they are a bastard to get out when they are stuck so firmly!
With a Dremel or angle grinder with a fine disc grind a groove on the head so you can use a screw driver.Don't try and grind the groove in one go,try several passes and cool the area down with water so that you don't melt the plastic from the sole.Freddie.
If you are having problems drill the hole it has nothing to do with the cordless.
Almost all cordless drills will have more than enough power to drill the hole needed. Hell I have drilled 19mm holes through 8mm steel with a cordless.
You need a very sharp drill bit. Not one that has been rattling around in the bottom of a drawer.
I have removed many cleat screws with no more than a cordless, sharp drill bit and a screw extractor.
Drill speed is more important than power. Small drills need much higher speeds than what you'll get from an average battery drill. There are charts that give the correct speed, which will vary depending on the metal you're drilling.
I can advise from personal experience NOT to use an angle grinder.
Not if you ever want to clip into anything with those shoes again.... Stupid angle grinder.
Zoom, I run a buisness building kitchens and alot of metal furniture! We use cordless drills every day of our lives. We dont own any corded drills and have never needed them for the drilling of steel. Most cordless drills spin fast enough for a 2-3mm drill bit in steel. Sure a power drill would do it quicker but a cordless drill will do it just fine!
I stick by my statement if you have a very sharp drill bit then almost any cordless aslong as you have charged the battery will drill a hole in a cleat screw. If it doesnt its not the tools fault its the person holding it!
That's fine. But talk to any lathe or mill operator and they will tell you there is an optimum speed for cutting metals. Do a Google search on drill speeds.
a few good ideas so far on how to get the bolt out
Myself, i normally tap a torx bit into where the allen key should be. Normally works first time every time. You just need to make sure its hammered in properly and you dont need a second bite at getting it undone
I was nearly brought to the brink by this problem a couple of weeks ago. I used a screw extractor, drilled the hole nicely, but the extractor snapped while trying to extract the screw. So then I had a snapped off screw estractor plugged in the middle of the cleat screw.
How I fixed it was nasty but effective. The screw wasn't seized in the thread, but fused to the oval washer thing that sits on the cleat.
So how I removed it was I used a screw driver to bend up the oval washer thing, and then used the pliers to turn it. Since the screw was fused to the oval washer it turned with the washer and screwed out nicely.
Messy but effective. This wouldnt work though if 2 cleat screws were seized, since you need to remove one screw to be able to bend up the washer.
Thanks for all the suggestions. I finally got it out after recharging the drill batteries to max and breaking 3 cheap drill bits in the process. It's even worse when there's broken drill bits inside the screw
Note to self: do not over tighten the screws!
Tom
Note to self: Use Lithium Grease on the new screws
Zoom, he is not turning up a precission part that needs everything perfect.
He is drilling a hole for a screw extractor! Most people have a cordless and thats all you need to drill the tiny hole required.
I am not saying a power drill wouldnt drill a better hole of couse it would! But by the time you have the power drill out and plugged in the cordless would have the job finished!