Ok OSOer's I need to replace my sending unit on my fuel tank in a Formula 312 Fastech. All Phillips head screws came out but the last one.(WTF). The screw came out 3/4 way and then the cross section for the screwdriver is now round..(dumb design) Bolts would have been better........ YUP I have a 3/4 tank of fuel...
Would drilling a hole in the screw (with oil) to use an easy out be asking for trouble and a big BOOM. or do you think at slow speed bursts I could get a hole in the screw to get the easy out in and get this screw out. Or break screw off. Install new sending unit. Drain tank best I can in winter and do it then..
Tired of guessing on fuel qty in tank.

Not enough room to get vice grips on it and turn it? 3/4 the way out it should be pretty easy to turn.

Don't know how much room you have to work with but if you can get a small pair of vise grips on the head of the screw try to turn it back in. Stand the vise grips as if it were a screwdriver. Put some CRC or WD40 on the threads first. Back the screw out until it gets a little tight then back in, continue back and forth and hopefully you can turn the screw out. I used hex head bolts to replace the Phillips screws in mine. Good luck!

+1.....and they should be 1/4-20

The sparks from inside the drill (brushes on commutator) can cause the gas to ignite!!! Don't use electric or battery tool around flammable gases. Guys with paint booths should have sealed motors on fans and sealed light switches in the booth and no power tools. Be safe and have a great boating adventure.

Fuel fill and one of the vent tubes is right there in my damn way... May be able to get a small vice grip on if in vertical
position and will be hard to get a good bite..Guess will have to work it some... Will be changing to bolts... Thanks all.

if you do end up needing to drill it out, use a pneumatic drill

+1

The new sending unit should come with hex head bolts/screws, mine did when I changed it out year before last.