Stripped sunken screw - how to remove?

I read this as the THREAD of the screw isn't stripped, but the cross for the Phillips screwdriver is obliterated to a smooth female cone?

If so drill out using a drill a bit smaller than a suitably sized Torx bit, so you can tap a bit into the hole and the bit's splines will bite hard within the drilled hole. Hopefully you can then undo what's left of the fastener.

But I think you said the handle the screw secures is scrap? Why can't you hacksaw a screwdriver slot in the screw even if you hacksaw into the handle as well in the process... ?

If It's a UPVC opening window frame they are easy to remove so you can work on it laid flat on the bench and use things like pillar drills. I mean the window laying flat on the bench, not you....

Edit: You MUST use a decent cobalt, known branded drill bit, not something from eBay of unknown origin and material, if you snap the drill inside the screw you're in a pickle...;)
 
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Would it be easier taking this part out of the window frame and then trying to get what's left of the screw out?

www.handlesandhinges.co.uk

Inline Window Espag by Maco

Inline window locking mechanisms and gearboxes for UPVC windows. Espag, shootbolt and reverse action available.
www.handlesandhinges.co.uk www.handlesandhinges.co.uk

Depends how much of it is left as to whether you can get it out of the slot where the gearbox bit is. Might take a bit of wiggling to get it out. I had to do the same thing as the screws seem to be really soft metal on handles. There was enough of the thread left to get some pliers on it to undo it. Replacement handles usually come with better screws. A dab of grease on the thread should stop any corrosion in the future.
 
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Drill it just enough so you can start a reverse thread tap in the drill hole?

Edit: Use a left handed drill bit to drill the hole for extra left handedness.
 
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Drilling was actually really easy in the end.

Drilled the stripped hole with a 5.5mm after measuring the thickness of the thread.
Took handle out. And removed screw turning with pliers.

WAaccay.jpg
 
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