DIY Guide How To Get Broken Drill Bit Out

Can you remove a broken drill bit? Yes, you absolutely can remove a broken drill bit with the right tools and techniques. This comprehensive guide will walk you through various methods to remove broken drill bit fragments, whether they’re stuck in wood, metal, or other materials. We’ll cover everything from simple household fixes to specialized tools designed to extract snapped drill bit pieces.

A broken drill bit is a frustrating problem that can halt your project in its tracks. Whether it snapped off during use or you accidentally broke it, the primary concern is how to remove broken drill bit pieces without causing further damage to your workpiece. Thankfully, there are several effective strategies you can employ to get that stubborn fragment out.

How To Get Broken Drill Bit Out
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Fathoming the Problem: Why Do Drill Bits Break?

Before we dive into removal techniques, it’s helpful to understand why drill bits break in the first place. Knowing the causes can help prevent future occurrences.

Using the Wrong Speed: Drilling too fast generates excessive heat and stress on the bit, leading to fracture.
Applying Too Much Pressure: Forcing the drill bit through material, especially hard ones, can cause it to bend and snap.
Dull Drill Bits: A dull bit requires more force and generates more heat, increasing the risk of breakage.
Material Hardness: Attempting to drill very hard materials with a bit not designed for them is a common cause of breakage.
Improper Angle: Drilling at an angle can put uneven stress on the bit.
Faulty Bit: Sometimes, a manufacturing defect can lead to a weak point in the drill bit.

Tools You Might Need to Remove Broken Drill Bit

The tools you’ll require depend on the method you choose and the material the bit is stuck in. Here’s a general list of helpful items:

Safety Glasses: Crucial for protecting your eyes from flying debris.
Center Punch: To create a starting point for drilling or extraction.
Hammer: For tapping punches or bits.
Pliers (Needle-nose and Regular): For gripping protruding fragments.
Penetrating Oil (e.g., WD-40): To loosen seized bits.
Left-Handed Drill Bits: These spin in reverse, sometimes catching the broken bit and backing it out.
Screw Extractors (Also known as broken screw extractor or use a screw extractor tools): Specialized bits designed to bite into broken pieces and turn them out.
Drill Bit Removal Tool: Some sets include specialized bits for this purpose.
Small Hacksaw or Dremel with Cutting Disc: For creating a slot if the bit is flush.
Vise Grips: For a stronger grip on larger protruding pieces.
Cutting Fluid or Lubricant: Essential when drilling into metal.
Small Drill Bits (for pilot holes): For use with screw extractors.
Welder (Advanced): For welding a nut onto a broken bolt or bit.

Simple Methods to Extract Snapped Drill Bit Pieces

When a drill bit snaps, you’ll often find a piece lodged in your workpiece. The goal is to get it out without damaging the surrounding material.

Method 1: Gripping and Twisting (If a Piece is Protruding)

This is the easiest scenario. If a bit of the drill bit is sticking out of the hole, you might be able to grab it and unscrew it.

Assess the Situation: Look closely to see if any part of the drill bit is accessible.
Apply Penetrating Oil: Spray a small amount of penetrating oil around the broken bit. Let it sit for a few minutes to help loosen any rust or debris.
Grip Firmly: Use a sturdy pair of needle-nose pliers or vise grips to get a strong hold on the protruding fragment.
Twist Counter-Clockwise: Slowly and steadily try to turn the bit counter-clockwise. If it moves, continue to gently unscrew it. If it’s very tight, apply a bit more penetrating oil and try again.
Wiggle Gently: Sometimes, gently wiggling the bit from side to side while twisting can help break it free.

Method 2: Using Pliers for Flush Breaks

If the bit is broken off perfectly flush with the surface, this method can still work if you can create a small grip point.

Clean the Area: Use a brush to clear away any metal shavings or debris from around the broken bit.
Apply Penetrating Oil: As before, a little penetrating oil can be a big help.
Create a Notch (If Necessary): If the bit is truly flush, you might need to carefully create a small notch on its edge using a small file or the edge of a sharp utility knife. This notch will give your pliers something to grip. Be very careful not to damage the surrounding material.
Grip and Twist: Once you have a grip point, use needle-nose pliers or vise grips to twist the bit counter-clockwise.

More Advanced Techniques to Remove Broken Drill Bit

When simple gripping doesn’t work, you’ll need to employ more specialized tools or methods.

Method 3: Using Left-Handed Drill Bits

Left-handed drill bits are designed to cut in reverse (counter-clockwise). This inherent characteristic can sometimes be enough to unscrew the broken bit.

Choose the Right Bit: Select a left-handed drill bit that is slightly smaller than the diameter of the broken drill bit fragment.
Center Punch: Place a center punch mark precisely in the center of the broken drill bit to guide your left-handed bit.
Drill Slowly in Reverse: Set your drill to the reverse (counter-clockwise) setting. Start drilling slowly into the center of the broken bit.
Apply Steady Pressure: As you drill, the reverse action of the left-handed bit may catch the broken fragment and begin to unscrew it from the hole.
Be Patient: If the bit doesn’t immediately back out, continue drilling slowly. The cutting action in reverse might just be enough to loosen it. If it starts to turn, continue to back it out.

Method 4: Employing a Screw Extractor (Broken Screw Extractor / Use a Screw Extractor)

Screw extractors, also known as “easy-outs,” are specifically designed to remove broken drill bit pieces and stripped screws. They work by biting into the material and providing a strong grip for removal.

Select the Correct Extractor Size: Screw extractor kits come with various sizes. You need an extractor that is smaller than the diameter of the hole but large enough to get a good bite on the broken bit.
Drill a Pilot Hole: This is a critical step. Use a standard drill bit (or a left-handed bit, which can be even better here) to drill a pilot hole directly into the center of the broken drill bit. The pilot hole should be deep enough to seat the extractor but not so deep that it goes through the other side of your workpiece. The size of this pilot hole will be specified by the extractor kit’s instructions.
Insert the Extractor: Gently tap the correct size screw extractor into the pilot hole with a hammer.
Turn Counter-Clockwise: Attach a tap wrench or your drill (set to reverse and at a slow speed) to the extractor. Turn it slowly and steadily counter-clockwise. The extractor’s reverse threading will bite into the broken bit.
Apply Consistent Pressure: As you turn, apply steady downward pressure. The extractor should grip the bit and start to back it out of the hole. If it feels like it’s slipping, you may need to tap it in a little deeper or use a different size extractor.

Table 1: Screw Extractor Size Guide (General)

Broken Bit Diameter (approx.)	Pilot Hole Size (approx.)	Extractor Size (approx.)
1/8″ – 3/16″	#10 – #20	#1
3/16″ – 1/4″	#20 – #30	#2
1/4″ – 5/16″	#30 – #40	#3
5/16″ – 7/16″	#40 – #50	#4

Note: Always refer to the specific instructions that come with your screw extractor kit for precise sizing.

Method 5: The Drill Out Method (Drill Out Broken Bit)

This method involves drilling out the broken bit itself. It’s more destructive but can be effective when other methods fail. The goal is to drill away the metal of the broken bit without damaging the surrounding material too much.

Center Punch Accurately: Precisely mark the center of the broken drill bit. This is paramount for success.
Use a Small, Hard Drill Bit: Start with a very small drill bit that is smaller than the diameter of the broken bit. Carbide-tipped bits are excellent for this, as they are very hard.
Drill Slowly with Lubricant: Set your drill to a slow speed and use plenty of cutting fluid or lubricant, especially if you are drilling out a drill bit stuck in metal. Drill directly down the center of the broken bit.
Gradually Increase Bit Size: As you drill deeper and remove material, you can gradually increase the size of your drill bit. The aim is to remove the bulk of the broken bit’s material.
Be Cautious of the Hole Walls: As you get closer to the diameter of the original hole, be extremely careful not to drill into the workpiece itself. If you accidentally enlarge the hole, you may need to consider filling it and re-drilling or using a dowel or plug.
Clean Out Debris: Periodically stop and clean out the metal shavings and debris.

Method 6: Using a Dremel or Rotary Tool

A Dremel with a thin cutting disc can be used to create a slot in the end of a broken drill bit if it’s flush or nearly flush.

Secure the Workpiece: Ensure the item with the broken bit is firmly secured.
Use a Cutting Disc: Attach a thin metal cutting disc to your Dremel.
Create a Slot: Carefully cut a slot across the end of the broken drill bit. Aim to cut deep enough to accommodate a flathead screwdriver.
Use a Screwdriver: Once the slot is made, use a flathead screwdriver that fits snugly into the slot to try and unscrew the broken bit.

Method 7: Welding a Nut (Advanced)**

This is a more advanced technique, typically used for broken bolts or studs, but it can also be applied to a broken drill bit, especially if it’s broken off in metal and you have welding equipment.

Clean the Area: Thoroughly clean the area around the broken drill bit.
Place a Nut: Find a nut that is slightly larger than the broken drill bit. Place it over the broken bit.
Weld the Nut: Carefully weld the nut to the top of the broken drill bit. Ensure a strong weld.
Cool Down: Allow the weld to cool completely.
Apply Heat and Penetrating Oil: Apply penetrating oil around the weld. You can also gently heat the nut (not the workpiece) with a torch to help expand it.
Use a Wrench: Use a socket wrench to turn the nut counter-clockwise. The heat and the nut’s grip should help unscrew the broken bit.

Dealing with a Drill Bit Stuck in Metal

When you have a drill bit stuck in metal, the process can be more challenging due to the material’s hardness and the tendency for metal to seize.

Penetrating Oil is Key: Always start with a good quality penetrating oil. Let it soak for a significant amount of time (hours, or even overnight if possible).
Heat Can Help: Applying localized heat to the surrounding metal with a torch can cause it to expand slightly, potentially loosening its grip on the drill bit. Be cautious not to overheat or warp the workpiece.
Hammer Tapping: Gently tapping around the area of the broken bit with a hammer can sometimes create vibrations that help break the bond.
Lubrication During Extraction: If you’re using a screw extractor or drilling out the bit, always use plenty of cutting fluid or lubricant designed for metal. This reduces friction, dissipates heat, and makes the process smoother.
Left-Handed Bits are Excellent for Metal: Because they cut in reverse, left-handed drill bits are particularly useful for extracting broken bits from metal. They have a better chance of grabbing and unscrewing the fragment.

What About a Broken Tap Removal?

While this guide focuses on drill bits, the principles for removing a broken tap are often similar, as taps are also essentially threaded cutting tools that can snap.

Taps are Often Harder: Taps are typically made from even harder steel than drill bits, making them more difficult to drill out.
Specialized Tap Extractors Exist: There are specific tools designed for removing broken taps, which often involve a special key or lever that fits into the flutes of the tap.
EDM (Electrical Discharge Machining): For very difficult broken tap situations, especially in hardened steel, EDM is the professional solution. It uses electrical sparks to erode the metal of the broken tap without damaging the surrounding material. This is usually a service provided by machine shops.

When to Call a Professional

While most broken drill bit situations are manageable with DIY methods, there are times when you should consider professional help:

Expensive or Critical Workpiece: If the material the bit is stuck in is valuable or critical for structural integrity, you might want to avoid the risk of DIY attempts.
Extremely Hard Materials: Drilling through hardened steel or specialized alloys can be very challenging.
Deeply Lodged Bits: If the bit is very deep or broken off in a complex or hard-to-reach area.
Lack of Proper Tools or Confidence: If you don’t have the right tools or feel uncomfortable attempting the removal, it’s best to seek expert assistance. Machine shops or experienced mechanics can often handle these situations.

Frequently Asked Questions (FAQ)

Q1: What is the best way to remove a broken drill bit?

A1: The best way depends on how the bit is broken and the material. If a piece is sticking out, pliers are best. If it’s flush, a screw extractor is often the most effective method.

Q2: Can I use a regular drill bit to drill out a broken drill bit?

A2: You can, but it’s challenging. It’s much easier and more effective to use a left-handed drill bit or a very hard carbide-tipped bit. Always use lubricant when drilling metal.

Q3: My drill bit broke off flush in a piece of metal. What should I do?

A3: Apply penetrating oil, use a center punch to make a divot, and then try a screw extractor. If that fails, consider drilling out the broken bit with progressively larger bits, using plenty of cutting fluid.

Q4: What if the screw extractor breaks off in the broken drill bit?

A4: This is a difficult situation. Screw extractors are hardened, making them hard to drill. You might need to try a carbide burr bit with a rotary tool to grind away the extractor, or consider professional help.

Q5: How do I prevent drill bits from breaking in the future?

A5: Use the correct speed and pressure for the material, ensure your drill bits are sharp, use the appropriate type of bit for the material (e.g., cobalt for metal), and always use cutting fluid for drilling metal.

Getting a broken drill bit out can be a test of patience and skill, but with the right approach, you can successfully salvage your project. Remember to prioritize safety, gather the necessary tools, and work methodically. Good luck!