Can you drill a screw out? Yes, you absolutely can drill a screw out, especially if it’s stripped or damaged. This guide will walk you through the methods for successfully drilling out screws and extracting damaged fasteners. We’ll cover everything from simple techniques for removing a stripped screw to more advanced methods for tackling a broken screw removal.
When a screw head is damaged, it can feel like a frustrating dead end for your project. Whether it’s a stripped head, a broken shank, or just a screw that refuses to budge, knowing how to drill a screw out properly is a valuable skill. This comprehensive guide will equip you with the knowledge and techniques to tackle most stubborn screw situations, ensuring you can proceed with your work without being held back by damaged fasteners. We’ll explore various scenarios and provide step-by-step instructions to help you extract damaged screws and bolts with confidence.
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When You Need to Extract a Damaged Screw
There are several common reasons why you might find yourself needing to extract a damaged screw. Recognizing these situations will help you choose the right approach:
- Stripped Screw Heads: This is perhaps the most frequent culprit. When the slots or recesses in a screw head become rounded, your screwdriver can no longer grip it effectively. Trying to force it only makes the stripping worse, making it difficult to remove a stripped screw.
- Broken Screw Shanks: Sometimes, a screw can break off at the head, leaving the threaded portion embedded in the material. This presents a challenge for a broken screw removal, as there’s no head to grip.
- Rusted or Corroded Screws: Metal screws can rust or corrode over time, effectively fusing them to the material they are in. These screws can be incredibly difficult to turn, and attempting to force them can lead to stripping or breakage.
- Over-Tightened Screws: Screws that have been excessively tightened can become lodged, making them nearly impossible to remove with standard tools.
- Damaged Threads: While less common for removal, sometimes the screw itself or the hole it’s in can have damaged threads, preventing easy extraction.
Basic Principles for Screw Removal
Before diving into drilling, it’s important to grasp some fundamental principles that can help you avoid damaging the screw or the surrounding material:
- Use the Right Tool: Always start with the correct screwdriver for the screw head type and size. A Phillips head needs a Phillips screwdriver, a flat head needs a flat head, and so on. Using the wrong type can quickly strip the head.
- Apply Downward Pressure: When attempting to turn a screw, apply firm downward pressure. This helps keep the screwdriver engaged in the head and prevents it from camming out and stripping.
- Turn Slowly and Steadily: Jerky movements are more likely to strip a screw head. Slow, consistent turning with controlled pressure is key.
- Consider Lubrication: For stubborn screws, especially those that might be rusted or corroded, a penetrating oil can work wonders. Apply it generously and let it soak for a while before attempting removal. This can help loosen rust or grime and make it easier to get a stuck screw out.
Methods for Removing a Stripped Screw
When you need to remove a stripped screw, several techniques can help you regain grip and extract it.
Method 1: The Rubber Band Trick
This is a simple and often effective method for screws with minor stripping.
What you need:
- A wide rubber band
- A screwdriver that fits the stripped screw head
Steps:
- Place the rubber band: Lay a wide rubber band flat over the stripped screw head.
- Insert the screwdriver: Press your screwdriver firmly into the screw head, ensuring it goes through the rubber band. The rubber band fills the gaps in the stripped head, providing extra grip.
- Turn slowly: Apply firm downward pressure and slowly turn the screwdriver counter-clockwise. The rubber band should give the screwdriver enough purchase to turn the screw.
Method 2: Using Pliers
If the screw head is still protruding enough to grip, pliers can be a viable option.
What you need:
- Locking pliers (vise-grips) or a good pair of regular pliers
- Gloves for better grip
Steps:
- Grip the screw head: Firmly clamp the jaws of the pliers onto the sides of the screw head. Locking pliers are ideal as they maintain a constant grip.
- Twist counter-clockwise: Once you have a secure grip, slowly twist the pliers counter-clockwise. Apply steady pressure. If the screw is still quite tight, you might need to wiggle it a bit while turning.
Method 3: Drilling a Pilot Hole and Using a Screw Extractor
This is a more involved method but highly effective for more severely stripped screws or when you need to drill a screw out without a head. A screw extractor kit is a specialized tool designed precisely for this purpose.
What you need:
- A drill
- A drill bit (slightly smaller than the screw shank)
- A screw extractor kit (also known as an easy-out set)
- Safety glasses
- Gloves
Steps:
- Select the right drill bit: Choose a drill bit that is slightly smaller than the diameter of the screw shank. You want to create a pilot hole in the center of the screw head without going too deep or damaging the surrounding material.
- Drill the pilot hole: Carefully and steadily drill a hole directly into the center of the stripped screw head. Use a slow drill speed and apply consistent pressure. The goal is to create a clean, centered recess for the extractor.
- Choose the correct extractor: Screw extractor kits come with various sizes. Select an extractor that fits snugly into the pilot hole you just drilled. The extractor will have reverse threads.
- Insert the extractor: Place the tip of the extractor into the pilot hole.
- Drill in reverse: Set your drill to reverse (counter-clockwise).
- Extract the screw: Apply steady downward pressure and slowly run the drill in reverse. The reverse threads of the extractor will bite into the screw head, and as you continue to turn, it will pull the damaged screw out. You can also use a tap handle or wrench with the extractor if your drill doesn’t offer enough torque or control.
Tackling Broken Screw Removal
When a screw breaks off, you’re left with the threaded portion embedded in the material, requiring a slightly different approach.
Method 1: The Screw Extractor Method (Again!)
This is the go-to method for broken screw removal.
What you need:
- A drill
- Drill bits (various sizes, including one for a pilot hole and potentially larger ones if the screw shank is exposed)
- A screw extractor kit
- Center punch
- Hammer
- Penetrating oil (optional but recommended)
- Safety glasses
- Gloves
Steps:
- Prepare the broken screw: If there’s any protruding piece of the screw, try to carefully grind or file it down so it’s flush with the surface. This gives you a flat starting point.
- Center punch: Use a center punch and hammer to create a small indentation directly in the center of the broken screw. This indentation will guide your drill bit and prevent it from wandering.
- Drill the pilot hole: Select a drill bit that is slightly smaller than the diameter of the broken screw shank. Drill a pilot hole directly into the center of the broken screw. Go slowly and keep the drill perfectly straight. The depth of the hole should be sufficient to engage the screw extractor.
- Select and insert the extractor: Choose the appropriate size screw extractor from your kit. The tapered, reverse-threaded end of the extractor is inserted into the pilot hole.
- Extract the screw: Attach a tap handle or wrench to the extractor. Turn the extractor counter-clockwise with firm, steady pressure. As you turn, the extractor’s threads will bite into the broken screw, and with continued rotation, the screw should start to back out.
Method 2: Drilling Out the Entire Screw
If the screw extractor fails or isn’t suitable, you can drill out the entire screw. This method destroys the screw but can save your project.
What you need:
- A drill
- Drill bits (starting small and gradually increasing in size)
- Center punch
- Hammer
- Penetrating oil (optional)
- Safety glasses
- Gloves
Steps:
- Center punch: Mark the center of the broken screw with a center punch.
- Start with a small drill bit: Begin by drilling a small pilot hole directly into the center of the broken screw. Use a bit that is significantly smaller than the screw’s diameter.
- Gradually increase drill bit size: Slowly increase the size of your drill bit. The goal is to drill away the material of the screw itself, working from the center outwards.
- Drill carefully: As you increase the drill bit size, you are essentially widening the hole through the screw. Be careful not to enlarge the hole beyond the diameter of the original screw threads, as this could damage the threads in the material you are working with.
- Remove remaining fragments: Once you’ve drilled out most of the screw, you can often pick out the remaining thread fragments with a small pick or needle-nose pliers.
- Re-tap the hole (if necessary): If the original threads in the material were damaged, you may need to re-tap the hole to create new, clean threads or use a slightly larger screw.
How to Drill a Screw Out Without a Head
When a screw head is completely missing, you are effectively dealing with a broken screw. The methods described for broken screw removal, particularly using a screw extractor or drilling out the entire screw, are your primary options. The key is to accurately locate and drill into the center of the remaining screw shank.
Using a Screw Extractor Kit Effectively
A screw extractor kit is an invaluable tool for dealing with stripped and broken screws. Here’s how to maximize its potential:
Types of Screw Extractors:
- Straight Flute Extractors: These have straight flutes and are less likely to expand the screw as they bite into it, which can be helpful for softer materials.
- Spiral Flute Extractors (Easy-Outs): These are the most common type. They have a tapered, reverse-threaded spiral design that bites into the metal as you turn.
Tips for Using a Screw Extractor:
- Start with the right size: Don’t force an extractor that’s too large into a small pilot hole. This can break the extractor, which is much harder to remove than the screw itself.
- Drill a clean, centered pilot hole: This is the most critical step for successful extraction.
- Use a slow drill speed: High speeds can generate heat and damage the extractor or the screw.
- Apply steady, consistent pressure: Avoid jerky movements.
- Consider left-handed drill bits: For particularly stubborn screws, a left-handed drill bit can sometimes catch the screw and back it out on its own as you drill the pilot hole.
- If an extractor breaks: This is a worst-case scenario. If the extractor breaks off in the screw, you might need to use a Dremel with a cut-off wheel to try and create a slot for a flat-head screwdriver, or you might have to drill out the entire screw.
When You Need to Drill Out a Bolt
Drilling out a bolt is similar to drilling out a screw, especially if the bolt head is damaged or broken off. The principles of centering, using appropriate drill bit sizes, and steady pressure apply.
Key Considerations for Bolts:
- Size and Strength: Bolts are generally larger and stronger than screws, meaning you might need more powerful drills and larger drill bits.
- Material: The material of the bolt and the material it’s fastened into will influence the best drill bit type and speed. Hardened steel bolts will require cobalt or titanium drill bits.
- Lubrication: For larger bolts, using cutting fluid or oil is highly recommended to keep the drill bit cool and reduce friction.
Steps for Drilling Out a Bolt:
- Center punch: Accurately mark the center of the bolt head or the broken shank.
- Pilot hole: Start with a small, sharp drill bit, preferably one made for metal. Drill a pilot hole in the center.
- Increase drill bit size: Gradually increase the drill bit size until you reach the diameter of the bolt’s threads. You are essentially drilling away the bolt’s material.
- Remove remnants: Once the bolt material is drilled out, you can often remove the remaining threads from the hole.
- Re-tap the hole: If the threads in the receiving material are damaged, you will need to re-tap the hole with the appropriate tap.
How to Ease Stripped Screw Issues
To ease stripped screw issues before they become major problems, consider these preventative measures:
- Use the right screwdriver: Always match the screwdriver to the screw head.
- Apply downward pressure: This is crucial to prevent cam-out.
- Don’t overtighten: Tighten screws until snug, not until you’re straining.
- Use a manual screwdriver for final tightening: Power drills can easily overtighten and strip screws.
Frequently Asked Questions (FAQ)
What is the best way to remove a stripped screw?
The best way to remove a stripped screw often depends on the severity of the stripping. For minor stripping, a rubber band or pliers can work. For more significant stripping, a screw extractor kit is highly recommended.
Can I drill out a screw with a stripped head?
Yes, you can drill out a screw with a stripped head. The process usually involves drilling a pilot hole in the center of the stripped head and then using a screw extractor or continuing to drill out the screw’s material.
How do you get a stuck screw out if the head is stripped?
To get a stuck screw out with a stripped head, you can try the rubber band trick, use pliers to grip the head, or employ a screw extractor. If these fail, drilling out the screw is the next step.
What if a screw extractor breaks in the screw?
If a screw extractor breaks in the screw, it’s a difficult situation. You may need to use a rotary tool (like a Dremel) with a grinding bit to carefully grind away the broken extractor or drill out the entire screw. Specialized extractor removal bits are also available.
How do I know which size screw extractor to use?
Screw extractor kits usually come with instructions or a guide that correlates pilot hole sizes to specific extractor sizes. Always aim for an extractor that fits snugly into the pilot hole you drilled without being too tight or too loose.
By following these detailed steps and employing the right tools, you can confidently tackle most situations involving stripped or broken screws, ensuring your projects continue smoothly.