Can You Tap A Stripped Screw Hole? Understanding Your Options

Tapping a stripped screw hole is a viable option to fix it, but it's important to note that the hole will need to be enlarged to accommodate a wider screw. This is because the screw threads have removed the wood or metal to its maximum diameter, leaving nothing for the screw to grip onto. While it is possible to use the same-sized screw for tapping, this will require the use of a threaded insert or coil, and the process becomes more complex. To tap a stripped screw hole, you'll need to select a wider screw, drill a new hole, and then use a tap-and-die set to create new threads. This process is suitable for both wood and metal surfaces, but it's important to choose the appropriate tools and techniques for the specific material you're working with.

The process of tapping a hole

Tapping a hole is the process of creating threads on the sides of a drilled hole to enable screwing in a bolt or machine screw. Here is a step-by-step guide on the process of tapping a hole:

Step 1: Drill the Hole

Determine the size of the hole you need to drill for the bolt you are trying to screw in. The hole will be smaller than the diameter of the bolt, as the threads tapped will increase the diameter. Drill the hole in the designated location, being conscious of how deep the hole is. If you are using a taper tap, you may need to drill a deeper hole to account for the part of the tap that doesn't create complete threads.

Step 2: Tapping the Hole

Now that you have a drilled hole, use a tap of the correct size and a tap handle to thread the hole. To begin tapping, rotate the taper bit clockwise until you feel resistance from the threads cutting into the material. From there, for every full rotation clockwise, make a half rotation counterclockwise. This will break off any chips that have been created and clear the space for the cutting teeth of the tap to keep cutting. Make sure to pay attention to any abnormal resistance and, when in doubt, back the tap out a few threads and retry. You can also use a lubricant to make tapping the hole easier.

Step 3: Cleaning and Testing the Hole

After you finish tapping the hole, remove the tap and clean out the chips from both the tap and the material. Compressed air can be helpful for removing chips, and you will also want to clean off any lubricant used. Once the hole and material are cleaned, test the threads of the hole with the bolt or machine screw you plan on using. If there is a lot of resistance and the bolt does not screw in easily, run the tap through the hole again.

Additional Tips:

• It is important to be conscious of how much depth will be able to be tapped and secured with whatever fastener you are using.
• Taps are very brittle, so the accumulation of chips or any other extra stress on the tap could cause it to break in the material.
• If you have used a taper tap to go all the way through the hole, or as deep as a blind hole will allow, you can use a bottom tap to complete the threading closer to the bottom of the hole.
• If you are working with thin materials, such as sheet metal, you may not be able to tap a hole.
• If you are working with low-density materials like plastic, particle board, or wood, consider using fasteners with High-Low threads, which are easier to install and have increased pull-out strength.

Alternative Methods to Fix a Stripped Screw Hole:

• If you are working with wood, the simplest fix is to use a longer screw that bypasses the stripped section and grabs deeper into the wood. Other methods include filling the hole with wood, using a plastic snap-off wood anchor, or lining the hole with a metal screen repair kit.
• If you are working with metal, other methods to fix a stripped screw hole include driving a wider-diameter screw, applying liquid stripped thread repair, adding a threaded metal insert, or creating new threads with a tap-and-die set.

Fixing a stripped screw hole in wood

Using a Longer or Wider Screw

The simplest fix for a stripped screw hole in wood is to replace the screw with a longer or wider screw. This method bypasses the stripped section and grabs deeper into the wood. When choosing a new screw, opt for one with slightly coarser and more aggressive threads, as they will bite into fresh wood more effectively. Make sure not to use too much force when driving in the new screw to avoid further stripping the wood.

Filling the Hole with Wood

Another method is to fill the stripped screw hole with wooden materials such as matchsticks, toothpicks, or wooden dowels. Cut off the heads of the matchsticks or toothpicks, and use wood glue to secure them in the hole. Snap off any excess material flush with the wood surface and sand it down if needed. Once the glue has dried, you can drive the screw directly into the filler material.

Using a Metal Screen Repair Kit

A metal screen repair kit can also be used to fix a stripped screw hole in wood. Cut long, narrow strips of the metal screen material and fit them lengthwise into the hole. The sharp ridges on the screen mimic screw hole threads, providing a better grip for the screw. After inserting the tip of the screw into the hole, tighten it down with a manual screwdriver.

Plastic Snap-Off Wood Anchor

This method involves using a cone-shaped polypropylene anchor as filler material for the new screw threads. Gently screw the anchor into the stripped screw hole with a manual screwdriver until it can no longer be turned without stripping. Snap off the excess part of the anchor flush with the wood surface, then turn the new screw into the anchor.

Screw Hole Repair Kit

Screw hole repair kits are also available, which typically consist of plastic anchors and glue. While these kits may work for simple applications, they are generally not the best option for most situations and can be more expensive than other DIY fixes.

Fixing a stripped screw hole in metal

If you have stripped a screw hole in metal, there are several ways to fix it. Here are some methods to try:

Using a Rubber Band

For smaller screws, sometimes all you need is a little extra traction for your screwdriver. Place a rubber band on top of the screw head. This provides the traction needed for the screwdriver to bite into the screw head, allowing you to twist and remove it. A thicker, broader rubber band is preferable as it provides a larger contact area.

Cutting a Slot into the Head

If you are dealing with a Philips or star head screw, and the head has been stripped, you can turn it into a flathead screw. Use a small hacksaw or a rotary attachment on a drill to cut a slot into the head. Be careful not to cut into the material underneath the screw. This method is only effective if the screw is not inserted too deeply into the metal.

Using a Left-Handed Drill Bit

Left-handed drill bits are designed to be used in reverse. Choose a drill bit thinner than the screw body for the best results. Place the left-handed drill bit into your drill, tighten it, and drill into the stripped screw. Once the bit bites, it will likely unscrew the problem fastener. This method may require a few attempts, so be patient.

Using Vise Grips

If the screw head is accessible, you can use vise grips to grip and turn the stripped screw directly. This method is straightforward and does not require any additional tools or modifications.

Using a Small Hammer and Drift Punch

If you have the wrong-sized Allen key, you can use a small hammer and a drift punch (flat bottom) to tap down the raised edges caused by the incorrect Allen key. Flatten the edges to the point where you need to tap the proper-sized Allen key into the bolt head. Then, turn out the damaged bolt and replace it with a correctly sized one.

Using an Impact Driver

Choose the correct screwdriver bit for your stripped screw, load it into the impact driver, and place it on the screw head. Hit the back of the driver with a hammer a few times. The impact driver will bite into the fastener and turn, loosening the screw until it can be removed with traditional tools. Be cautious, as too much impact can damage the screw head, making it even more difficult to remove.

Remember to exercise patience and caution when attempting any of these methods. Good luck with your repair!

Removing a stripped screw from wood

Use a Rubber Band

A rubber band can be an effective way to increase traction and grip when trying to remove a stripped screw. Place a rubber band, preferably a wide one, over the top of the stripped screw. Then, firmly insert the tip of your screwdriver and slowly try to unscrew it. The rubber band will add traction and create a better grip for your screwdriver, making it easier to twist the screw.

Try a Different Screwdriver

If you're using a Phillips-head screwdriver, try switching to a flat-head screwdriver that is narrow enough to fit within the Phillips-head hole. This method requires a bit of muscle, but it can be effective. For added grip, you can also combine this technique with the rubber band method mentioned above.

Screw Extractor

If the screw is being stubborn and won't come out, it's time to bring out the screw extractor. Screw extractors are designed with counter-threads, meaning they have a left-hand twist while screws have a right-hand twist. Choose the right size of screw extractor to fit into the screw head. Load it into your drill, set the drill to reverse, and let the extractor do its job. As you drill in reverse, the extractor will start turning the screw in the opposite direction, backing it out of the wood.

Pliers

If the screw head stands above the wood surface, clamping a pair of locking pliers onto the screw can be a simple solution. Position the pliers as close as possible to the wood surface and gently turn the screw counterclockwise. Work slowly to avoid snapping off the head of the screw. If the screw head is flush with the wood and you don't want to risk damage, consider using a screw extractor first to expose more of the screw.

Drill a Hole

Another option is to drill a small hole into the stripped screw head. This will allow your screwdriver to reach deeper and achieve a better grip. Make sure to use a drill bit designed for metal, not wood, and be careful not to drill too far down to avoid the screw head popping off. After drilling, place your screwdriver into the hole and twist it slowly to remove the screw.

Other Tips

• Cover the area around the screw with tape to prevent damage to the wood surface.
• If the screw is made of soft metal, use a hammer to gently tap a flat-head screwdriver into the screw head, providing a firmer grip.
• For added traction, place a small piece of steel wool on top of the screw head and insert the screwdriver through it.
• If the screw is completely stripped and you can't salvage it, consider using a wood plug cutter to remove the material around the screw and gain access to it.

Removing a stripped screw from metal

• Use a different driver: Try using a manual flathead screwdriver instead of a Phillips head screwdriver. Angle the blade into the screw head and apply force. Once about 1/4-inch of the screw is exposed, clamp locking pliers to the sides of the screw head and turn it the rest of the counterclockwise. Alternatively, use a larger driver bit or screwdriver that is slightly bigger in diameter to fill the void in the stripped screw head.
• Bypass the stripped screw head: If the screw head is exposed, bypass the stripped section by gripping the screw with locking pliers and turning it counter-clockwise until it releases.
• Use a rubber band: Place a rubber band between the screwdriver tip and the stripped screw head. This adds grip and fills in gaps, making it easier to turn the screw.
• Use a manual screwdriver: A manual screwdriver provides more torque and control compared to an electric drill, making it easier to apply pressure without risking further damage to the screw.
• Use steel wool: Place a small piece of steel wool on top of the screw head and insert the tip of the screw through it. Press down while turning the screw counter-clockwise to increase friction.
• Tap with a hammer: Gently tap a manual screwdriver into the screw head with a hammer to seat the tip slightly deeper into the screw, providing a better grip.
• Cut a slot into the screw head: Use an electric tool, such as a rotary cutting tool or a multi-tool with a metal blade, to cut a shallow groove in the screw head. Then, insert the tip of a flat-head screwdriver into the groove and turn it counter-clockwise.
• Use an abrasive: Apply a powder or liquid abrasive to the screw head to increase friction and improve grip. You can use non-chlorinated cleaning powder, fine sand, or grip friction drops.
• Use a screw extractor kit: If other methods are unsuccessful, a screw extractor kit is a reliable option. Drill a hole in the screw with the forward-threaded drill bit, then switch to the reverse-threaded drill bit to remove it.
• Tap with a hammer: If the screw is rusted, tap it with a small hammer to break up the rust before using a screw extractor kit.
• Use a wider-diameter screw: For sheet metal, you may need to use a larger screw to grip the metal. Choose a screw that fits without being too big for peripheral items like hinges or brackets. Drive the screw manually or with a low-speed electric drill.
• Liquid stripped thread repair: Apply a liquid stripped thread repair solution to create new threads. Mix the two-part solution and fill the screw hole halfway. Insert the desired screw into the liquid and allow it to harden before removing and re-inserting the screw.
• Add a threaded metal insert: If you need to retain the original diameter of the screw hole, use a threaded metal insert. Determine the screw diameter and pitch, then select the correct size of threaded metal insert. Bore out the hole, apply cutting oil, and use a tap to create threads in the hole before inserting the threaded metal insert.
• Cut threads with a tap-and-die set: If you can enlarge the screw hole, use a tap-and-die set to create new threads. This method is similar to the threaded insert approach but without the insert.

Frequently asked questions