stripped allen wrench screws

I agree that I wouldn't tap anything into the screw head but using an easy-out should not involve having to tap it in if the right size easy-out is used.

The taper of the tip of the easy-out is likely extreme enough that the flutes will bite into the sides of the recess when the handle is turned counter-clockwise. I'm not guaranteeing it will work but it's an inexpensive experiment and won't make the situation worse if it doesn't.

If the screws are not recessed, and you have replacement screws available, I recommend you buy a Dremel, and with the cut-off wheel attached, carefully cut a flat slice into the top of the screw so you can remove it with a flat-blade screwdriver.

Just hold onto the Dremel for dear life so it doesn't walk off the screw and cut your unit top.

Steve

I've normally have found success without having to go as far some of the above suggestions, even if they are salient.

What I recommend you try first is to switch from metric to SAE or vice versa. More often than not, you can go up a tad in size for the wrench, and get enough of a grip on the bolt to remove it.

Mc,
I'd NEVER want to use a Dremel around my fine electronics. All it'd take was a single metal flake / chip / particle to short between a couple board traces and you'd be .......well, really mad at yourself.

chayro: do you mean 'Torx'?