How To Remove Broken Allen Heads From Screws

If you've broken off an Allen key in a screw, don't panic—there are a few ways to fix this. One method is to use a screw extractor kit, or, if the screw isn't tight, grab it with pliers and turn. You can also use a small drill bit or a pointed Dremel bit to slowly widen a hole in the screw until it breaks and falls out. Alternatively, you can cut a slot in the top of the screw with a Dremel and then use a flathead screwdriver to remove it.

Using a screw extractor kit

Step 1: Gather the Right Tools

First, make sure you have the right tools for the job. You will need a drill, drill bits (unless your extractor has a boring end), thread cutting oil or penetrating oil, safety glasses, and gloves (optional but recommended).

Step 2: Prepare the Screw

Put on your safety glasses and gloves. If your screw extractor doesn't have a boring end, you will need to create space in the screw head for it to work. You can do this by drilling or expanding a hole in the old screw. Start by aligning a punch with the center of the screw and hammering it lightly to create an indentation. This will guide your drill bit and help prevent slipping.

Step 3: Drill a Guide Hole

Select a drill bit that is slightly narrower than the screw and attach it to your drill. If your screw is rusted or affixed to metal, apply a small amount of penetrating oil to help loosen its grip. Now, slowly drill straight down into the screw head by about 1/8 to 1/4 inch. Take your time and be careful not to rush this step to avoid damaging your workpiece.

Step 4: Use the Screw Extractor

Finally, it's time to use your screw extractor. Place the pointed threaded end of the extractor into the hole you drilled. If your extractor has a tap handle, attach it and turn it counterclockwise by hand or with a wrench. If your extractor fits into a drill, put it into the drill and set it to reverse. Keep turning the extractor counterclockwise until the screw is completely removed.

Tips and Troubleshooting:

• If the screw is still difficult to remove, try drilling a little more of the head or using the next size up for the extractor.
• For extremely stubborn screws, consider manually turning the extractor by hand or with a wrench instead of using a drill. This can reduce the risk of breaking the extractor bit.
• Always wear safety glasses and gloves when using a screw extractor to protect yourself from flying metal shards and sharp edges.

With these steps, you should be able to successfully remove a broken Allen screw using a screw extractor kit.

Using a flathead screwdriver

Step 1: Prepare the Screw

Before you start, make sure you have the right safety gear, including safety glasses to protect your eyes from any metal shards. If you have sensitive skin, consider wearing gloves as well.

Step 2: Choose the Right Flathead Screwdriver

Select a flathead screwdriver that is slightly larger than the stripped screw. This will help the screwdriver catch on the screw head and create more friction to turn the screw.

Step 3: Tap the Screwdriver with a Hammer

Place the tip of the flathead screwdriver on the top of the stripped screw. Then, lightly tap the end of the screwdriver handle 2-3 times with a hammer. This will help the screwdriver dig into the screw head and create more friction.

Step 4: Try to Turn the Screw

Without lifting the screwdriver, try to turn the screw counterclockwise to see if you can loosen it. You may need to tap the screwdriver a few more times with the hammer to create more friction and help the screwdriver grip the screw.

Step 5: Apply Penetrating Oil or Heat (Optional)

If the screw is still not turning, you can try applying a penetrating oil, such as WD-40, to the screw and waiting for it to set in. This can help lubricate the screw and make it easier to turn. Alternatively, you can try heating the area around the screw with a heat gun or blow torch and then allowing it to cool before attempting to turn the screw again.

Step 6: Use Pliers (Optional)

If the screw head is exposed and raised, you can try gripping it with pliers and turning it counterclockwise to remove it. This may be easier if you first file the sides of the screw head to make them flatter so that the pliers are less likely to slip.

Step 7: Cut a New Slot with a Rotary Tool (Optional)

If the above methods are not successful, you can try cutting a new slot in the screw head using a rotary tool and a cutting disc. This will create a fresh surface for the flathead screwdriver to grip. Position the cutting disc vertically and turn on the rotary tool. Then, lightly press the tool into the screw head to make a straight line across the surface. Make sure the slit is close to the size of the flathead screwdriver to ensure a proper fit.

Step 8: Remove the Screw

Once you have created a new slot with the rotary tool, fit the end of the flathead screwdriver into the slot and turn it counterclockwise to remove the stripped screw.

Drilling the screw out

If an Allen key or wrench head breaks off inside a screw, one option is to drill out the screw. This method is useful if the screw is stripped and you don't have access to a screw extractor kit or other tools.

To begin drilling the screw out, choose a drill bit that is about the same diameter as the screw's threads and put it into your drill. Wear safety glasses before you start. Apply light downward pressure and use a low and slow speed to drill straight through the screw. When you're finished, you can easily pull out what's left of the screw with a pair of needlenose pliers.

If the space is very small, you may need a stronger drill bit than you have. In this case, it may be worth seeking professional help or investing in better tools.

If you don't want to drill the screw out, there are other methods you can try. One option is to use a screw extractor kit. Screw extractors have a cutting drill bit on one end and a removal bit on the other. First, put the extractor into your drill with the cutting bit exposed and drill a shallow hole in the middle of the screw head. Then, flip the extractor over to the removal bit. Place the removal bit in the new hole and set your drill to reverse to unscrew the screw.

Another option is to use a centre punch. A centre punch has a pointed end that's spring-loaded. Place the bit on a flat part of the screw head so the sharp end points to the left. Pull up on the spring and let go to apply force to the screw. The bit will catch in the screw head and turn the screw with each hit. If the screw doesn't turn, try tapping the back of the punch's handle with a hammer.

You can also try using a rubber band, pliers, a hammer and screwdriver, friction drops, a Torx wrench, or epoxy to remove the screw.

Using a rubber band for added traction

If an Allen key or wrench has broken off inside a screw, it can be incredibly frustrating. Luckily, there are a few methods you can try to remove the screw. One such method is to use a rubber band for added traction. Here is a step-by-step guide:

Step 1: Choose the Right Rubber Band

Select a rubber band that is wider than the screw head. It needs to completely cover the hex hole of the screw. A single, thick rubber band is usually best for this task. If you don't have a rubber band, you can try using steel wool or the green, abrasive side of a sponge instead.

Step 2: Position the Rubber Band

Place the rubber band over the stripped screw, pressing part of it flat against the screw head. Hold it firmly in place with one hand. If needed, reposition the object with the screw so you have better access to it. For example, if the screw is in a board, try clamping the board in a vise to keep it steady while you work.

Step 3: Insert the Screwdriver

Push the Allen wrench or screwdriver into the rubber band and screw head. Ensure that the rubber band goes inside the hex hole and moulds to the screw threads. This will create leverage for the screwdriver. Hold the screwdriver steady, and if the rubber band falls out, simply put it back in place.

Step 4: Turn the Screwdriver

Apply firm but slow force to turn the screwdriver counterclockwise to remove the screw. Work slowly, as the screw will still be difficult to turn. Maintain firm pressure on the rubber band and gradually turn it. You should feel the screw start to loosen. If necessary, reposition the rubber band and continue until you can remove the screw.

Troubleshooting:

Even if you follow these steps carefully, the rubber band method may not always work. If this happens, try using other tools to remove the screw. Here are some additional methods you can try:

• Use a hammer to gently tap the back end of the screwdriver a few times to wedge it deeper into the screw. This can help the screwdriver get a better grip on the screw threads.
• Drill through the screw with a power drill and a 1/8-inch (0.32 cm) drill bit. Position the drill bit in the centre of the screw head and drill straight down until you reach the bottom of the screw head. Then, try removing the screw with the screwdriver and rubber band again.
• Cut into the screw with a rotary tool, such as a Dremel. Use a metal-cutting disk to deepen the screwdriver slot. Then, insert the rubber band and screwdriver to attempt removal again.

Applying friction drops to the Allen wrench

Friction drops are a great way to give your Allen wrench extra grip when trying to remove a stripped screw. Here is a detailed, step-by-step guide on how to apply friction drops effectively:

Preparing the Screw and Allen Wrench

• Ensure you have the correctly-sized Allen wrench for the stripped screw. It is important to use the proper size to avoid further stripping.
• Clean the screw head and the Allen wrench to ensure that there is no dirt or debris that could hinder the friction drops from working effectively.
• Dry the screw head and the Allen wrench completely. The friction drops will work best on a dry surface.

Applying the Friction Drops

• Place a drop or two of friction drops inside the hex hole of the stripped screw. Make sure to use enough, but don't overdo it.
• Quickly insert the Allen wrench into the hex hole, ensuring it is seated as deeply as possible. You may need to give it a few light taps with a hammer to ensure it is fully seated.
• With the Allen wrench in the hex hole, wiggle it around a few times to help the friction drops catch and fill in any gaps between the wrench and the stripped hex hole.
• Once you are satisfied that the friction drops have caught and created a grip, apply counter-clockwise pressure to the screw to start removing it. Remember to turn the screw counter-clockwise to loosen it.

Tips and Tricks

• Make sure to use the correct size of Allen wrench. Using the wrong size can further strip the screw and make it even more difficult to remove.
• If the friction drops are not providing enough grip, you can try using a different type of wrench, such as a Torx wrench, or you can try using a rubber band or paper to create more friction.
• Be careful not to get the friction drops on any surrounding surfaces, as they may leave stains or be difficult to remove.
• If you are having trouble getting the Allen wrench to catch, try tapping it lightly with a hammer to help it seat properly.

Frequently asked questions