Stripped, broken, seized, and rusted screws are the bane of any DIYer’s existence. They can bring even the most ambitious project to a screeching halt. But don’t despair! With the right tools and techniques, you can remove even the most stubborn screw. In this article, we’ll walk you through the steps on how to remove a screw that broke off. We’ll cover five different methods, so you’re sure to find one that works for your situation.
The first step is to assess the situation. What type of screw is it? What material is it made of? How badly is it damaged? Once you know what you’re dealing with, you can choose the best method for removing it. If the screw is only slightly stripped, you may be able to remove it with a pair of pliers or a screw extractor. However, if the screw is badly damaged, you may need to drill it out.
No matter which method you choose, safety should be your top priority. Always wear safety glasses and gloves when working with power tools. And be sure to read the instructions for your specific tool before using it. With a little patience and care, you’ll be able to remove that broken screw in no time.
Assessing the Situation: Identifying the Extent of the Breakage
When a screw breaks off, it’s crucial to assess the situation thoroughly to determine the extent of the breakage. This will help you choose the most appropriate removal method.
Types of Breakage
| Breakage Type | Description |
|---|---|
| Partial Break | A portion of the screw’s head or shaft has snapped off, leaving some threads intact. |
| Complete Break | The screw head or shaft has broken off entirely, leaving no threads exposed. |
| Flush Break | The screw head has broken off flush with the surface of the material. |
| Stripped Head Break | The screw head has been stripped or damaged, making it difficult or impossible to grip with a tool. |
Assessing the Breakage
To assess the breakage accurately:
- Identify the location of the break: Determine whether the screw broke off at the head, shaft, or in the middle.
- Inspect the remaining screw: Check for any visible threads, damage to the head, or stripping.
- Measure the depth of the hole: Use a depth gauge or ruler to measure the distance from the surface of the material to the bottom of the screw hole.
- Determine the size of the screw: Identify the diameter and length of the screw to select the appropriate removal tool.
- Identify the material of the screw: Knowing whether the screw is made of metal, plastic, or another material will influence the removal method.
Safety First: Choosing the Appropriate Tools and Safety Gear
When dealing with a broken screw, safety should be your top priority. Before attempting to remove it, gather the necessary tools and safety gear to prevent injuries or further damage.
Tools for Screw Removal
Choose the right tools for the job based on the type of screw and its location. Common tools include:
- Needle-nose pliers
- Vice grips
- Screw extractors
- Left-handed drill bits
- Hammer and punch
Safety Gear
Protect yourself with proper safety gear. Wear eye protection, gloves, and a dust mask to avoid flying debris or metal shavings from getting into your eyes or lungs. Ensure your work area is well-ventilated to prevent breathing in any harmful fumes.
| Eye Protection | Gloves | Dust Mask |
|---|---|---|
| Safety glasses or goggles | Nitrile or rubber gloves | N95 or higher |
By following these safety precautions and selecting the appropriate tools, you can safely and effectively remove that pesky broken screw.
Center Punch: Precision Placement for Success
Mark the Center
The first step is to pinpoint the center of the broken screw. Use a center punch and lightly tap its tip on the screw’s head. This will create a small indentation that serves as a precise target for the next step.
Optimal Force
Applying the right amount of force is crucial. Too little may not create a visible mark, while too much can damage the surrounding material. Start with a delicate touch and gradually increase the force until you see a faint indent.
Accurate Alignment
Alignment is key. Hold the center punch perpendicular to the screw’s surface. If it’s at an angle, the indentation will be off-center, affecting the accuracy of the extraction process. To ensure correct alignment, use a straight edge or a ruler as a guide.
| Center Punch Tips |
|---|
| Use a sharp punch to create a precise indentation. |
| Apply just enough force to make a visible mark. |
| Align the punch perpendicular to the screw’s surface. |
| If possible, use a straight edge or ruler for guidance. |
| If the screw is deeply recessed, use a punch with a longer handle for better leverage. |
Screw Extractor: Extracting Broken Screws with Efficiency
A screw extractor, also known as an easy-out or screw remover, is a tool designed to remove damaged or broken screws. It is typically made of hardened steel and features a spiral-shaped tip that bites into the broken screw, allowing it to be easily extracted.
Selecting the Right Screw Extractor
Choosing the right screw extractor is essential for successful screw removal. It is important to consider the size and type of the broken screw, as well as the material it is made of. The extractor should be slightly smaller in diameter than the broken screw to ensure a good fit. Additionally, the extractor’s tip should match the head shape of the broken screw (e.g., Phillips, hex, slotted).
Here is a table summarizing the different types of screw extractors and their applications:
| Type of Screw Extractor | Application |
|---|---|
| Spiral Screw Extractor | General-purpose extractor for most types of screws |
| Stubby Screw Extractor | Used in confined spaces or when the screw head is recessed |
| Fluted Screw Extractor | Suitable for soft or damaged screws |
| Square Screw Extractor | Ideal for extracting large or heavily torqued screws |
Once the appropriate screw extractor has been selected, it can be used to extract the broken screw in the following steps:
- Drill a pilot hole into the center of the broken screw.
- Insert the screw extractor into the pilot hole and tap it gently with a hammer.
- Turn the screw extractor counterclockwise using a wrench or screwdriver.
- Continue turning until the broken screw is extracted.
Reverse Drilling: A Delicate Approach for Precise Removal
When a screw breaks off, reverse drilling becomes the preferred technique for its removal. This method involves the use of a drill bit slightly smaller than the screw’s diameter, which is then carefully inserted into the broken screw and rotated in reverse. As the drill bit engages, it begins to cut away the broken screw, allowing it to be gradually extracted.
5. Step-by-Step Guide to Reverse Drilling:
| Step | Instructions |
|---|---|
| 1. Safety First: | Wear safety glasses and gloves to protect yourself from flying metal fragments. |
| 2. Choose the Right Drill Bit: | Select a drill bit that is slightly smaller (about 1/16 inch) than the diameter of the broken screw. |
| 3. Center the Drill Bit: | Carefully center the drill bit on the broken screw, ensuring it is perpendicular to the surface. |
| 4. Start Drilling: | Slowly and gently rotate the drill in reverse, applying light pressure. As the drill bit engages, you will feel it begin to bite into the metal. |
| 5. Extract the Broken Screw: | Continue drilling in reverse until the screw’s head becomes visible. Once the head is exposed, switch to a pair of pliers or needle-nose tweezers to carefully grasp and remove the broken screw. |
Grip it and Rip it: Using Locking Pliers for Firm Hold
Employing locking pliers provides an unparalleled grip on the exposed screw portion. This technique is particularly effective when the screw is recessed or flush with the surface. Select a pair of pliers with a locking mechanism that securely holds the jaws in place, preventing slippage. Once the pliers are firmly attached to the screw, apply steady pressure while attempting to twist it counterclockwise. The locked jaws ensure maximum torque transmission, increasing the chances of success.
To further enhance grip, consider utilizing a rubber band or piece of leather between the pliers and the screw. This additional layer creates extra friction, reducing the likelihood of the pliers slipping and damaging the screw further.
Screw Extraction Using Locking Pliers: Step-by-Step Instructions
| Step | Description |
|---|---|
| 1 | Securely attach locking pliers to the exposed screw portion, ensuring a firm grip. |
| 2 | Apply steady pressure while twisting the pliers counterclockwise, aiming to extract the screw. |
| 3 | If necessary, place a rubber band or a piece of leather between the pliers and the screw for additional grip. |
| 4 | Continue applying pressure and twisting until the screw is fully extracted. |
Lefty Loosey: Counterclockwise Rotation for Removal
When a screw breaks off, the most common solution is to use a counterclockwise rotation to remove it. This is known as the “lefty loosey” method.
1. Inspect the Screw Head
Determine the type of screw head (e.g., Phillips, flathead) and ensure you have the appropriate screwdriver.
2. Center the Screwdriver
Position the screwdriver firmly against the center of the screw head to maximize grip.
3. Apply Force
Apply downward pressure while turning the screwdriver counterclockwise. Use moderate force initially to avoid stripping the screw head.
4. Increase Leverage
If the screw remains stuck, use a longer screwdriver or attach it to a wrench for increased leverage.
5. Lubricate the Screw
Apply a penetrating oil or lubricant to the screw threads to reduce friction and ease removal.
6. Tap the Screwdriver
Lightly tap the screwdriver handle with a hammer while turning counterclockwise. This may help loosen the screw.
7. Grip the Broken Screw
If access to the broken screw is available, use a pair of pliers with needle-nose tips to grip the screw and rotate it counterclockwise. To improve grip, you can insert the broken screw into a wooden block or vice.
| Tool | Description |
|---|---|
| Needle-nose pliers | Small, pointed pliers for gripping small screws |
| Wooden block | A piece of wood with a depression to hold the broken screw |
| Vice | A clamping tool that can hold the broken screw securely |
Dremel Tool: Precision Cutting for Stubborn Screws
The Dremel tool is more versatile as it can perform various tasks, including cutting. It’s particularly useful when working with screws that have snapped off, as the tool’s precision and control allow for exact cuts. To remove a screw with the Dremel tool, follow these steps:
- Attach a cutting disc or burr bit to the Dremel tool.
- Secure the workpiece in a vise or clamp.
- Wear safety goggles and gloves.
- Start the Dremel tool and gently touch the disc or burr to the screw.
- Slowly guide the tool along the screw’s edge, applying gentle pressure.
- Continue cutting until the screw is completely severed.
- Remove the cut screw from the workpiece.
- Use a flat-head screwdriver or pliers to remove any leftover screw fragments.
- Clean the workpiece and Dremel tool thoroughly.
- Optional: Apply lubricant to the screw to prevent future breakage.
Using a Dremel Tool for Screw Removal: Safety Tips
When using the Dremel tool for removing screws, follow these safety precautions:
- Wear appropriate safety gear, including goggles, gloves, and a dust mask.
- Ensure that the workpiece is securely fastened to prevent accidents.
- Keep the Dremel tool away from your face and body.
- Avoid overexerting the tool, as this can cause damage.
- Allow the Dremel tool to cool down periodically to prevent overheating.
Soldering Iron: Fusing Broken Screws for Extraction
This method utilizes a soldering iron to fuse the broken screw to an extraction tool. Follow these steps:
- Clean the surface: Remove any dirt or debris around the broken screw using a wire brush or sandpaper.
- Apply flux: Apply a small amount of flux to the broken screw. Flux aids in the flow of solder.
- Heat the screw: Hold the soldering iron tip onto the broken screw and heat it until it becomes hot enough to melt solder.
- Apply solder: Touch the solder wire to the heated screw, allowing the solder to flow around the broken screw and form a small bead.
- Attach extraction tool: Insert the extraction tool (such as a screwdriver or hex key) into the solder mound and allow it to cool completely.
- Remove the screw: Once the solder is cool, carefully turn the extraction tool to remove the broken screw.
- Clean the area: Use a solder wick or flux remover to remove any excess solder from the surface.
- Check the screw: Inspect the removed screw to ensure it is still usable. If not, you may need to replace it.
- **Choose the right solder:** Select a solder with a melting point that is lower than the screw’s material. For example, use lead-free solder for aluminum screws and lead-based solder for steel screws.
10. Using a Drill Bit to Extract Screws
Materials Required:
- Drill bit (slightly smaller in diameter than the screw head)
- Drill with reverse function
- Eye protection
- Screwdriver or pliers
Steps:
- Lubricate the Screw: Apply penetrating oil or lubricant to the broken screw head. Let it soak for a few minutes to penetrate the threads.
- Mark the Screw Head: Use a center punch or a nail to mark the center of the broken screw head.
- Choose the Correct Drill Bit: Select a drill bit that is slightly smaller in diameter than the screw head. This will create a pilot hole without engaging the threads.
- Drill the Pilot Hole: Holding the drill perpendicular to the surface, carefully drill a pilot hole into the center of the screw head. Drill down to a depth slightly less than the length of the screw.
- Reverse the Drill: Set the drill to reverse mode and slowly drill into the hole. This will cause the drill bit to engage the threads and reverse the screw out of the material.
- Apply Light Pressure: Avoid applying excessive pressure while drilling in reverse. If the drill bit binds, stop drilling and try a smaller bit.
- Grip the Screw: Once the screw head is visible, use a screwdriver or pliers to grip it and remove it completely.
How to Remove a Screw That Broke Off
When a screw breaks off, it can be a frustrating and challenging problem to fix. However, there are a few simple steps you can take to safely and effectively remove the broken screw.
- Assess the situation. Before you start trying to remove the broken screw, take a moment to assess the situation. Make sure that the screw is not in a critical location, and that you have the proper tools to remove it.
- Use a screw extractor. A screw extractor is a specialized tool that is designed to remove broken screws. Screw extractors are available in a variety of sizes, so you will need to choose one that is the correct size for the screw you are trying to remove.
- Drill a hole in the screw. If a screw extractor is not available, you can try to drill a hole in the screw. To do this, use a drill bit that is slightly smaller than the diameter of the screw. Drill the hole carefully, and be sure to avoid drilling into the surrounding material.
- Use a reverse drill bit. A reverse drill bit is a drill bit that is designed to turn in the opposite direction of a regular drill bit. This can be helpful for removing broken screws, as it can help to loosen the screw and make it easier to extract.
- Use pliers or a vise. If the screw is still stuck, you can try to grip it with pliers or a vise. Be careful not to apply too much force, as you could damage the screw or the surrounding material.
If you are unable to remove the broken screw yourself, you may need to contact a professional. A professional will have the tools and experience to safely and effectively remove the broken screw.
People Also Ask
How do I remove a stripped screw without a screw extractor?
There are a few ways to remove a stripped screw without a screw extractor. One way is to use a pair of pliers or a vise to grip the screw. Another way is to use a rubber band to create friction between the screw and the screwdriver. You can also try to use a Dremel tool to grind a slot into the screw so that you can use a screwdriver to remove it.
How do I remove a broken screw from a wall?
To remove a broken screw from a wall, you can try to use a pair of pliers or a vise to grip the screw. If the screw is still stuck, you can try to drill a hole in the screw and use a screw extractor to remove it. You can also try to use a reverse drill bit to loosen the screw and make it easier to extract.
How do I remove a broken screw from a car?
To remove a broken screw from a car, you can try to use a pair of pliers or a vise to grip the screw. If the screw is still stuck, you can try to drill a hole in the screw and use a screw extractor to remove it. You can also try to use a reverse drill bit to loosen the screw and make it easier to extract.
