Getting frustrated with a stripped Allen screw is a common problem faced by DIY enthusiasts, professionals, and homeowners alike.
Whether it’s due to using the wrong tool, applying too much force, or simply a result of wear and tear, a stripped Allen screw can be a real nuisance.
However, there are several methods to remove a stripped Allen screw without causing further damage to the surrounding material.
In this comprehensive guide, we will explore various techniques and tools that can help you tackle this issue effectively.
Understanding Stripped Allen Screws
Before diving into the methods, it’s essential to understand what a stripped Allen screw is and why it occurs.
A stripped Allen screw is a screw, typically with a hexagonal recess, where the edges of the recess have been worn down, making it difficult for the Allen key or wrench to grip and turn the screw.
This can be caused by:
- Using an incorrect or worn-out Allen key or wrench
- Applying excessive force while tightening or loosening the screw
- Misalignment between the screw and the tool
- Corrosion or rusting of the screw
Tools and Materials You Might Need
Depending on the technique you choose to remove a stripped Allen screw, you may need some or all of the following tools and materials:
- Screw extractor kit
- Hammer
- Pliers
- Screwdriver (flathead and Phillips)
- Cold chisel
- Rotary tool or metal saw
- Allen key or wrench (preferably with a hexagonal profile)
- Torch or heat gun
- Penetrating oil or spray
- Vice grip or adjustable wrench
- Safety goggles and gloves
Now, let’s dive into the various methods on how to remove a stripped Allen screw.
1. Using a Screw Extractor Kit
A screw extractor kit is a specialized tool designed specifically for removing stripped and damaged screws.
These kits usually come with a range of extractor bits that can be used with a drill or a manual handle. Here’s how to use a screw extractor kit:
Step 1: Choose the Right Extractor Bit
Select an extractor bit that’s slightly smaller than the stripped Allen screw.
The bit should be able to fit snugly into the damaged recess without causing further damage.
Step 2: Prepare the Screw
Place the tip of the extractor bit into the stripped recess and tap it gently with a hammer to create an initial indentation.
This will help the extractor bit grip the screw better.
Step 3: Remove the Screw
Attach the extractor bit to a drill or manual handle and turn it counterclockwise.
Apply steady pressure while turning the extractor bit, and the stripped Allen screw should start to come loose.
2. Using Pliers or Vice Grips
If the head of the stripped Allen screw is protruding slightly from the surface, you can try using a pair of pliers or vice grips to remove it.
Here’s how:
Step 1: Clean the Area
Remove any dirt or debris from the area around the screw to ensure a better grip.
Step 2: Grip the Screw Head
Adjust the pliers or vice grips to fit securely over the screw head, ensuring a firm grip without slipping.
Step 3: Turn the Screw
While maintaining a strong grip on the screw head, turn the pliers or vice grips counterclockwise to remove the stripped Allen screw.
3. Creating a New Indentation with a Hammer and Chisel
If the screw’s recess is too damaged for other methods, you can create a new indentation to help turn the screw.
Here’s how:
Step 1: Clean the Area
As with other methods, begin by cleaning the area around the stripped Allen screw to ensure a better grip.
Step 2: Position the Chisel
Place the tip of a cold chisel (or a flathead screwdriver) at an angle on the edge of the screw head, aiming for a point where the chisel can gain traction.
Step 3: Tap the Chisel
Using a hammer, gently tap the chisel to create a new indentation on the screw head.
Step 4: Turn the Screw
Insert a flathead screwdriver into the new indentation and turn it counterclockwise to remove the stripped Allen screw.
4. Cutting a New Groove with a Rotary Tool or Metal Saw
Another method to create a new grip on the stripped Allen screw is by cutting a new groove into the screw head.
This can be done using a rotary tool or a metal saw. Here’s how:
Step 1: Set Up the Tool
Attach a cutting disc to your rotary tool or select a metal saw with a fine-toothed blade.
Step 2: Cut the Groove
Carefully cut a straight groove across the top of the screw head, deep enough for a flathead screwdriver to gain traction.
Step 3: Turn the Screw
Using a flathead screwdriver, turn the screw counterclockwise to remove it.
5. Applying Heat to the Screw Head
In some cases, applying heat to the screw head can help loosen it, making it easier to remove.
However, this method should not be used on wooden surfaces or near flammable materials. Here’s how to apply heat to the screw head:
Step 1: Clean the Area
Before applying heat, clean the area around the screw head to prevent any accidental fires.
Step 2: Heat the Screw Head
Using a torch or heat gun, apply heat directly to the screw head for a few seconds. Be careful not to overheat the surrounding area.
Step 3: Remove the Screw
Once the screw head has been heated, use a pair of pliers or an Allen key or wrench to turn the screw counterclockwise and remove it.
6. Using Penetrating Oil or Spray
If the stripped Allen screw is stuck due to corrosion or rust, applying a penetrating oil or spray can help to loosen it.
Here’s how to use penetrating oil or spray:
Step 1: Clean the Area
Start by cleaning the area surrounding the stripped Allen screw to ensure the penetrating oil can reach the screw threads.
Step 2: Apply the Penetrating Oil
Spray a generous amount of penetrating oil around the screw head, allowing it to seep into the threads.
Step 3: Wait for the Oil to Penetrate
Allow the penetrating oil to work for at least 15 to 20 minutes, or as directed by the product instructions.
Step 4: Remove the Screw
Use a pair of pliers or an Allen key or wrench to turn the screw counterclockwise and remove it.
7. Tapping the Screw with a Hammer and Screwdriver
A simple method to help loosen a stripped Allen screw is by tapping it with a hammer and screwdriver.
This can create a slight shock, potentially loosening the screw’s grip on the surrounding material.
Here’s how to tap the screw:
Step 1: Position the Screwdriver
Place the tip of a flathead screwdriver on the screw head, ensuring it is aligned with the center of the screw.
Step 2: Tap the Screwdriver
Using a hammer, gently tap the handle of the screwdriver, applying a series of quick, light blows.
Step 3: Remove the Screw
After tapping the screw, try using a pair of pliers or an Allen key or wrench to turn the screw counterclockwise and remove it.
8. Using a Rubber Band or Grip-enhancing Material
A simple trick to help grip a stripped Allen screw is by using a rubber band or grip-enhancing material between the tool and the screw head.
Here’s how to use this method:
Step 1: Position the Rubber Band
Place a small piece of a rubber band, grip-enhancing material, or even a piece of duct tape over the stripped recess.
Step 2: Insert the Tool
Press the Allen key or wrench firmly against the rubber band or material, allowing it to mold into the damaged recess.
Step 3: Turn the Screw
While maintaining pressure on the tool, turn it counterclockwise to remove the stripped Allen screw.
9. Using an Oversized Allen Key or Wrench
If you have an Allen key or wrench that’s slightly larger than the stripped recess, you can try using it to create a new grip on the screw.
Here’s how:
Step 1: Position the Oversized Tool
Insert the oversized Allen key or wrench into the stripped recess, ensuring it’s aligned correctly.
Step 2: Tap the Tool
Using a hammer, gently tap the handle of the Allen key or wrench, driving it further into the stripped recess.
This will create a tighter fit between the tool and the screw.
Step 3: Turn the Screw
Once the oversized tool is firmly seated, turn it counterclockwise to remove the stripped Allen screw.
10. Drilling Out the Screw
As a last resort, if none of the other methods have worked, you can try drilling out the stripped Allen screw.
However, this method should be used with caution, as it can potentially damage the surrounding material.
Here’s how to drill out the screw:
Step 1: Select the Right Drill Bit
Choose a drill bit that’s slightly smaller than the diameter of the screw. This will help prevent damage to the surrounding material.
Step 2: Drill a Pilot Hole
Carefully drill a pilot hole in the center of the screw head, applying steady pressure and ensuring the drill is aligned properly.
Step 3: Remove the Screw
Once the pilot hole has been drilled, use a pair of pliers or an Allen key or wrench to turn the screw counterclockwise and remove it.
Additional Tips for Removing Stripped Allen Screws
- Always wear safety goggles and gloves while working with tools to protect your eyes and hands.
- Work slowly and patiently to avoid causing further damage to the screw or the surrounding material.
- If the screw is particularly stubborn or the material is delicate, consider consulting a professional for assistance.
Preventing Stripped Allen Screws
To avoid encountering a stripped Allen screw in the future, follow these tips:
- Use the correct size Allen key or wrench for the screw to ensure a proper fit.
- Apply even pressure when tightening or loosening screws to avoid stripping the recess.
- Keep your tools clean and in good condition, as worn or damaged tools can cause screws to strip.
- If you notice a screw starting to strip, stop using it immediately and replace it with a new one.
Conclusion
There are various methods and tools available for removing a stripped Allen screw. By following the techniques outlined in this guide, you should be able to tackle this common issue effectively and without causing further damage to the surrounding material.
Remember, patience and the right approach are crucial to successfully removing a stripped Allen screw.
Shery
