Extracting A Stripped Allen Head Screw: Effective Strategies

Removing a stripped Allen head screw can be a frustrating task. However, there are several methods that can be used to get the job done. One common approach is to use a rubber band or rubber glove to add extra grip to the Allen wrench. Another option is to apply friction drops to the Allen wrench, which will help it grip the screw better. For screws that are sticking out, channel lock or vise grip pliers can be used to latch onto the screw and turn it counterclockwise. If the head of the screw is stripped, an oscillating tool or angle grinder can be used to cut a slot in the screw head, allowing a flathead screwdriver to be used for removal. In some cases, it may be necessary to drill out the screw using a screw extractor or a regular drill bit. For screws that are difficult to access, a Torx wrench or bit can be used, which has a star shape that provides more grip. With the right tools and techniques, removing a stripped Allen head screw can be a straightforward process.

Removing a stripped allen head screw

Use a Torx wrench

If you have a stripped Allen head screw, one of the methods you can use to remove it is a Torx wrench. Torx wrenches are designed for Torx screws, which have a six-pointed star pattern. The six points of the star pattern can nestle into a stripped Allen screw, providing enough purchase to loosen the screw.

First, choose a Torx wrench with a bit that is slightly larger than the hole in the stripped screw. Push the bit of the Torx wrench into the hole firmly, then turn the wrench counterclockwise to get the stripped screw out.

If you don't have a Torx wrench, you can buy a set from your local hardware store or online.

It's important to note that while the stripped screw probably won't strip any further, the Torx wrench tip might start to fail, so go slowly and carefully.

Apply friction drops

Friction drops are a great way to remove a stripped Allen screw. This method is simple and can be done with tools you may already have at home.

Friction drops are a solution with fine-grit metal powder that fills in the gaps between your wrench and the stripped hex hole. They can be purchased online or at your local hardware or auto parts store.

To use friction drops, simply add a drop or two of the solution to the hex hole. Then, push your Allen wrench into the hole and wiggle it a few times to help the drops catch. Finally, unscrew the screw counterclockwise.

If the friction drops method does not work, there are other ways to remove a stripped Allen screw. One way is to use a rubber band or rubber glove to add additional grip. You can also try using channel-lock pliers to latch onto the screw and turn it counterclockwise.

Cut a slot with an angle grinder

If you're dealing with a stripped Allen screw, one way to remove it is to cut a slot in the screw head with an angle grinder. Here's how you can do it:

First, put on a pair of safety glasses to protect your eyes from any metal debris. Next, use a marker or a pencil to draw a line on the top of the screw head as a guide for cutting the slot. Now, it's time to get your angle grinder. An angle grinder is a power tool with a rotating circular blade designed to cut through metal. Hold the grinder with both hands and position the blade on the line you drew on the screw head. Start the grinder and gently apply pressure to cut a straight, shallow slot in the top of the screw. Take your time and be careful not to cut too deep, as you don't want to damage the underlying surface.

Once you've created the slot, grab a flat-head screwdriver that fits snugly into the slot. Place the screwdriver in the slot and turn it counterclockwise to remove the stripped Allen screw. If needed, gently tap the screwdriver with a hammer to help loosen the screw.

If you don't have an angle grinder, you can also use a rotary tool with a grinding wheel or a hacksaw to cut the slot. Alternatively, you can try chiselling a slot with a flat-head screwdriver and a hammer. However, an angle grinder will give you the most precision and control for this task.

Try a screw extractor

If you're dealing with a stripped Allen screw, a screw extractor kit can be a great solution. Screw extractors fit onto your drill and cut through the screw to pull it out.

Screw extractor kits are much like a set of left-hand drill bits, but they are heavier and larger in diameter. They start at 3/16-inch and can be found at your local hardware store or online for around $10-20. They are also reusable, so you can keep one in your toolbox for future use.

Here's how to use a screw extractor:

• Put the extractor in your drill with the cutting bit exposed.
• Drill a shallow hole in the middle of the screw head.
• Flip the extractor over to the removal bit.
• Place the removal bit in the new hole you just made.
• Set your drill to reverse to unscrew the screw.

Before using a screw extractor, it's a good idea to try simpler methods first, such as using a rubber band or paper to improve grip, switching to a T-handle hex wrench for better grip and pressure, or adding a drop of screw-grab friction fluid. If none of these methods work, then it's time to break out the screw extractor.

Heat the screw

Heating a stripped Allen screw is one of the many ways to remove it. This method works best for removing a stripped Allen screw from metal.

• Put on a pair of safety glasses to protect your eyes from any debris or sparks.
• Light a butane or propane torch.
• Hold the tip of the flame over the screw head for 5 to 10 seconds. Be careful not to overheat the screw and avoid letting it get red hot.
• Once the screw is heated, quickly insert your Allen wrench into the screw head.
• Try turning the screw or bolt counterclockwise to loosen and remove it completely.

Note: Always exercise caution when using a heat source to remove screws or bolts. Avoid using this method on delicate or flammable materials to prevent damage or accidents.

Frequently asked questions