Stripped Allen screws can be a major headache, especially if you don’t have the right tools or experience. However, with a little patience and the right techniques, you can remove a stripped Allen screw without damaging the surrounding area. In this article, we will provide you with step-by-step instructions on how to remove a stripped Allen screw, as well as some tips on how to prevent this from happening in the future.
To begin removing a stripped Allen screw, you will need to gather a few tools. These tools include a pair of needle-nose pliers, a small flathead screwdriver, and a rubber band. Once you have your tools assembled, you can begin the following process: First, try to grip the stripped screw with the needle-nose pliers. If this does not work, you can try using the flathead screwdriver to gently pry the screw out of the hole. If neither of these methods works, you can try using a rubber band to create more friction between the screwdriver and the screw. Finally, if all else fails, you can try drilling out the screw using a drill bit that is slightly smaller than the diameter of the screw. However, this should only be done as a last resort, as it can damage the surrounding area.
To prevent stripped Allen screws in the future, there are a few things you can do. First, make sure to use the correct size Allen key for the screw. Second, apply downward pressure when tightening the screw, and avoid overtightening. Finally, use a thread locker to help keep the screw in place. By following these tips, you can help to prevent stripped Allen screws and keep your projects running smoothly.
Using a Reverse Drill Bit
A reverse drill bit, often known as an extractor bit, is a specialized tool designed to remove broken or stripped Allen screws. It typically features a left-hand twist that allows it to engage with the damaged screw and gradually extract it by turning it in the opposite direction of its original insertion.
Selecting the Right Reverse Drill Bit
Choosing the appropriate reverse drill bit size is crucial for successful screw removal. The bit should have a slightly smaller diameter than the damaged screw’s head so that it can effectively grip the remaining material. Refer to the table below for recommended drill bit sizes based on Allen screw sizes:
| Allen Screw Size | Reverse Drill Bit Size |
|---|---|
| M2 or #2 | 1.5mm |
| M3 or #3 | 2mm |
| M4 or #4 | 2.5mm |
| M5 or #5 | 3mm |
| M6 or #6 | 4mm |
Drilling and Extracting the Screw
- Secure the workpiece to prevent it from moving during the operation.
- Set your drill to a low speed and reverse rotation.
- Place the reverse drill bit on the screw head and apply gentle pressure.
- Apply continuous pressure while the drill slowly engages with the damaged screw.
- Once the drill bit bites into the screw, gradually increase the pressure and speed.
- Drill until the screw is completely extracted from the workpiece.
Tips:
- Use a sharp reverse drill bit to optimize performance.
- Apply a small amount of lubricant to the screw head to reduce friction.
- If the screw is deeply recessed, use a shorter reverse drill bit or create a small recess in the surrounding material to accommodate the drill bit.
- Be patient and avoid applying excessive force, which can damage the workpiece or the drill bit.
Employing an Extractor Tool
Extractor tools, specifically designed to remove stripped screws, offer a precise and effective solution. Their reverse-threaded design bites into the damaged screw head, creating friction and grip. These tools come in various sizes and styles, including spiral extractors, screw extractors, and left-handed drill bits.
To use an extractor tool:
- Choose the appropriate extractor size, slightly smaller than the damaged screw head.
- Insert the extractor into an impact driver or drill.
- Set the drill to the lowest speed setting.
- Align the extractor with the damaged screw and press firmly while drilling in reverse.
- As the extractor bites into the screw, slowly increase the drill speed.
- Once the screw is fully engaged, the extractor will turn it out of the hole.
Tips:
- Use a penetrating lubricant on the screw before using the extractor.
- Ensure the extractor is securely inserted into the drill or impact driver.
- Apply firm but controlled pressure while drilling in reverse.
The following table provides a guide to recommended extractor sizes for different screw diameters:
| Screw Diameter | Extractor Size |
|---|---|
| #4 – #6 | 1/16 inch |
| #8 – #10 | 3/32 inch |
| #12 – #14 | 1/8 inch |
| #16 – #18 | 5/32 inch |
| #20 – #24 | 3/16 inch |
Heating the Screw with a Soldering Iron
Using a soldering iron to heat the screw is another effective method for loosening the threads and breaking the bond between the screw and the surrounding material. The heat will cause the screw and the surrounding metal to expand, breaking the threads and making it easier to remove the screw. However, this method should be used cautiously, as excessive heat can damage the screw and the surrounding material.
To use this method, first, gather the necessary tools and materials:
- Soldering iron
- Solder
- Heat-resistant gloves
- Safety glasses
Once you have gathered the necessary tools and materials, follow these steps:
- Put on heat-resistant gloves and safety glasses to protect yourself from heat and solder spatter.
- Heat the soldering iron to the desired temperature.
- Apply the soldering iron to the head of the stripped screw and heat it for 10-15 seconds.
- Remove the soldering iron and immediately insert an Allen wrench into the screw.
- Turn the Allen wrench counterclockwise to remove the screw.
- Select a flathead screwdriver that closely matches the width of the screw head.
- Position the screwdriver tip into the stripped screw head at a slight angle.
- Apply downward pressure on the screwdriver and gently tap the handle with a hammer or mallet to create a slight impact.
- Simultaneously, apply torque by rotating the screwdriver counterclockwise to loosen the screw.
- Continue tapping and rotating the screwdriver until the screw begins to loosen.
- Once the screw is loose enough to grip with pliers, switch to this method for complete removal.
- Put on safety glasses.
- Attach a small grinding bit to the Dremel tool.
- Hold the Dremel tool perpendicular to the screw.
- Gently grind away the head of the screw.
- Once the head of the screw is removed, you can use pliers to remove the rest of the screw.
If the screw is still difficult to remove, you may need to reheat it for a longer period of time. However, be careful not to overheat the screw, as this can damage the screw and the surrounding material.
| Advantages of Heating the Screw with a Soldering Iron | Disadvantages of Heating the Screw with a Soldering Iron |
|---|---|
| Heats the screw and the surrounding material, breaking the threads. | Can damage the screw and the surrounding material if the heat is too high. |
| Can loosen stripped screws that are difficult to remove with other methods. | Requires a soldering iron and solder, which may not be readily available. |
| Relatively easy to perform. | Can be dangerous if not performed carefully, as it involves heat and solder. |
Applying Superglue and a Hex Key
If the hex key continues to slip, you can try applying a small amount of superglue to the tip of the key. Make sure to let it dry completely before trying to remove the screw. Once the superglue has dried, gently insert the key into the screw and apply pressure. The superglue will help to create a stronger bond between the key and the screw, making it less likely to slip.
Once you have a good grip on the screw, slowly turn it counterclockwise to remove it. Be patient and don’t apply too much pressure, as this could damage the screw or the surrounding material.
Here’s a summary of the steps involved in using superglue and a hex key to remove a stripped Allen screw:
| Step | Action |
|---|---|
| 1 | Apply a small amount of superglue to the tip of the hex key. |
| 2 | Let the superglue dry completely. |
| 3 | Insert the hex key into the screw and apply pressure. |
| 4 | Slowly turn the screw counterclockwise to remove it. |
Utilizing a Screw Extractor
A screw extractor is a specialized tool designed to remove damaged or stripped screws. It consists of a hardened steel bit that is tapered and has reverse threads. Here’s a step-by-step guide on how to use a screw extractor:
Prepare the Work Area:
Ensure the work area is well-lit and has sufficient space. Secure the workpiece using a vise or clamp to prevent it from moving while extracting the screw.
Select the Correct Extractor Size:
Choose a screw extractor that is slightly smaller than the stripped screw’s diameter. This will ensure a snug fit and optimal grip on the damaged threads.
Create a Pilot Hole:
Using a drill bit that is smaller than the extractor, carefully create a pilot hole in the center of the stripped screw. Drill to a depth that is equal to or slightly deeper than the length of the extractor.
Insert the Extractor:
Insert the screw extractor into the pilot hole and turn it counterclockwise using a wrench or vice grips. Apply moderate pressure while turning to avoid breaking the extractor.
Remove the Screw:
As the extractor engages with the stripped threads, it will gradually bite into the screw. Apply steady pressure and continue turning the extractor counterclockwise until the screw loosens and can be removed.
| Helpful Tips | |
|---|---|
| Use a drill press for greater precision when creating the pilot hole. | |
| Lubricate the extractor with penetrating oil to improve grip and reduce friction. | |
| If the screw is deeply embedded, may require drilling multiple pilot holes of increasing diameters. |
Drilling Out the Screw
If all other methods have failed, you may need to resort to drilling out the screw. This is a more drastic measure and should only be attempted as a last resort.
Step 1: Gather Your Tools
You will need:
– A drill
– A drill bit slightly smaller than the stripped screw
– A screw extractor
– A hammer
– Safety glasses
Step 2: Wear Safety Gear
Always wear safety glasses when working with power tools.
Step 3: Center the Drill Bit
Use a hammer to gently tap the screw extractor into the stripped screw. This will help to center the drill bit.
Step 4: Drill a Pilot Hole
Use the drill to drill a pilot hole in the center of the stripped screw. The pilot hole should be slightly smaller than the screw extractor.
Step 5: Insert the Screw Extractor
Insert the screw extractor into the pilot hole. Tap it in gently with a hammer.
Step 6: Extract the Screw
Use the drill to turn the screw extractor counterclockwise. The screw should start to come out. If it does not come out easily, you may need to use a larger drill bit to create a larger pilot hole.
| Drill Bit Size | Screw Size |
|—|—|
| 1/16 inch | #4 to #6 screws |
| 1/8 inch | #8 to #10 screws |
| 3/16 inch | #12 to #14 screws |
| 1/4 inch | #16 to #18 screws |
Utilizing a Flathead Screwdriver
A flathead screwdriver offers another approach for extracting stripped Allen screws. This technique is particularly useful when the screw head is accessible and not recessed within a countersunk hole.
Procedure:
Here’s a table summarizing the steps:
| Step | Description |
|---|---|
| 1 | Select a matching flathead screwdriver. |
| 2 | Position the screwdriver at an angle in the screw head. |
| 3 | Tap the screwdriver handle and apply torque simultaneously. |
| 4 | Continue tapping and rotating until the screw loosens. |
| 5 | Use pliers to remove the loosened screw. |
Applying Vice Grips
Vice grips, also known as locking pliers, offer a secure hold on a stripped Allen screw head. Follow these detailed steps to use vice grips effectively:
Materials:
| Item |
|---|
| Vice grips |
Instructions:
1. Position the jaws of the vice grips around the stripped Allen screw head.
2. Ensure that the jaws are aligned with the screw threads.
3. Gradually tighten the vice grips until they grip the screw head firmly.
4. Hold the vice grips steady with one hand while using the other hand to turn the screw.
5. Apply steady pressure and try to unscrew the screw.
6. If the screw does not move initially, increase the grip of the vice grips slightly.
7. Continue turning the screw with the Allen key while applying pressure with the vice grips.
8. Extended Grip Technique: If the screw remains stuck, try the following advanced technique:
– Position a small piece of metal (e.g., a washer or nut) between the jaws of the vice grips and the screw head.
– Tighten the vice grips to grip both the screw head and the metal piece.
– The added grip and increased leverage should help break the screw loose.
9. Once the screw begins to move, continue turning it with the Allen key until it is fully removed.
Using a Dremel Tool
If you have a Dremel tool, you can use it to remove a stripped Allen screw. Here’s how:
Using a Dremel to Remove a Stripped Allen Screw
There are a few things to keep in mind when using a Dremel to remove a stripped Allen screw:
| Tip | Description |
|---|---|
| Use a sharp bit | A sharp bit will cut through the screw more easily and cleanly. |
| Be careful not to grind too deeply | If you grind too deeply, you could damage the material around the screw. |
| Wear safety glasses | Grinding can produce small pieces of metal that could fly into your eyes. |
Grinding a Slot for a Flathead Screwdriver
Materials Needed:
– Rotary tool or Dremel
– Grinding bit
– Safety glasses
– Gloves
This method involves creating a slot in the stripped screw head using a rotary tool. Here’s a step-by-step guide:
Step 1: Prepare the Screw
Securely hold the object containing the stripped screw and wear safety glasses and gloves. Clean the screw head to remove any debris.
Step 2: Grind a Slot
Using a grinding bit, carefully grind a straight slot into the center of the screw head. Make it wide enough to accommodate a flathead screwdriver.
Step 3: Chamfer the Edges
To prevent the screwdriver from slipping, chamfer the edges of the slot slightly using a grinding bit or a file.
Step 4: Insert the Screwdriver
Choose a flathead screwdriver that fits snugly into the slot. Insert the screwdriver and carefully apply downward pressure while turning.
Step 5: Remove the Screw
Continue turning the screwdriver with firm pressure until the screw loosens and can be removed. If the screw is particularly stubborn, apply a small amount of penetrating oil to the slot.
Tips:
– Use a low speed setting on the rotary tool to minimize damage to the screw.
– Keep the grinding bit perpendicular to the screw head to create a straight slot.
– If the slot becomes too wide or damaged, grind a new one in a different location.
– If the screw still resists removal, consider using an extractor tool or heat to break the bond between the screw and the material.
How to Remove a Stripped Out Allen Screw
When an Allen screw becomes stripped, it can be difficult to remove. However, there are a few different techniques that you can try to get the screw out without damaging the surrounding material.
One way to remove a stripped out Allen screw is to use a rubber band. Place the rubber band over the head of the screw and then try to turn the screw with an Allen wrench. The rubber band will create extra friction, which can help to grip the screw and turn it loose.
Another technique that you can try is to use a pair of pliers. Grip the head of the screw with the pliers and then try to turn the screw loose. Be careful not to apply too much force, as this could damage the screw or the surrounding material.
If the screw is still stuck, you may need to use a drill to remove it. Drill a small hole into the center of the screw and then insert an Allen wrench into the hole. Try to turn the screw loose with the Allen wrench.
People Also Ask
How can I prevent Allen screws from becoming stripped?
There are a few things that you can do to prevent Allen screws from becoming stripped. First, make sure that you are using the correct size Allen wrench. Second, apply pressure straight down on the screw when you are turning it. Third, do not overtighten the screw.
What should I do if I strip an Allen screw?
If you strip an Allen screw, you can try one of the techniques described above to remove it. If you are unable to remove the screw, you may need to contact a professional.
Can I use a regular screwdriver to remove an Allen screw?
No, you cannot use a regular screwdriver to remove an Allen screw. Allen screws have a hexagonal head, which requires an Allen wrench to remove.
