I wanted to give my Saturn controller a clean due to some of the buttons feeling somewhat sticky. However, I can't undo the last screw. I tried all the screwdrivers in my universal screwdriver kit. So I suspect my screw has been destroyed. Does anyone know any viable method for getting it out without destroying the controller?
That doesn't look completely destroyed. With a proper screwdriver head you could probably remove it. I think you tried removing it with too small heads and you chipped off the inside.
I quickly checked and PH0, PH1, and SL1.5 heads seem to work the best. PH00 works but it's too loose. PH000 and SL1.0 are too small, the rest of the flat heads are too big. I don't have larger phillips heads to test.
Wish I knew how to tell the exact dimensions / head types to use for a screw.
I've tried elastic bands and super glue, but haven't gotten them to work. Sadly all the examples of how to remove stripped screws apply to larger screws that your average tradesmen would encounter. Being in an inlet also adds to the difficulty.. Currently, I'm going nuclear and trying to melt it out with a soldering iron (I don't have a drill unfortunately). Even that takes while due having to expand and contract the screw.
You'd need to pry it out while it's still hot enough to melt the plastic, to get it out that way. Given that you need to heat up the entire screw to a high enough temperature for that, you'd need an iron with very high performance (not high temperature, but high performance).
If I was going ballistic like that, I'd just try to pry half of the controller case out a few degrees, so it pushes against the screw, and then try rotating it. With luck it might loosen it up enough so there's no force holding it back and you can just twist it out with some pliers. Of course, the plastic might break.