Dealing with a stripped Allen (hex) screw is frustrating, but it's a common problem with a variety of solutions. This guide will walk you through several methods, from the simplest to more advanced techniques, to help you remove that stubborn screw. Remember safety first – always wear appropriate eye protection.
Assessing the Damage: What Kind of Stripping Are We Dealing With?
Before you begin, take a moment to assess the damage. This will help you choose the best approach.
- Slightly Rounded Edges: If the edges are just slightly rounded, you might still have enough grip for a standard Allen wrench. Try a fresh, high-quality wrench that fits snugly. Applying penetrating oil beforehand can help.
- Severely Rounded Edges: If the edges are significantly rounded or completely gone, you'll need more aggressive techniques.
- Screw Head Broken Off: If the screw head has broken off, you'll need to employ methods to grip and extract the remaining shank.
Methods for Removing Stripped Allen Screws
Here are several methods, starting with the simplest:
1. Penetrating Oil and a Fresh Wrench: The Simple Approach
Often, the easiest solution is the best. Apply a good quality penetrating oil (like PB Blaster or Liquid Wrench) to the screw head. Let it soak for at least 15-20 minutes (or even longer for stubborn screws). Then, try using a new, high-quality Allen wrench that fits snugly. Apply steady, firm pressure – avoid jerking or applying excessive force that could further damage the screw.
2. Rubber Band Trick: Adding Grip
A simple rubber band can provide extra grip. Place a rubber band over the stripped screw head before inserting your Allen wrench. The rubber band will help create more friction, giving you a better grip.
3. Using a Grip-Enhancing Tool: Screw Extractors and Similar Tools
For more severely stripped screws, you'll need specialized tools:
- Screw Extractors: These are specifically designed to grip and remove stripped screws. They have reverse-threaded tips that bite into the screw and unscrew it. Choose the correct size for your screw.
- Allen Key with a Grip: Consider buying an Allen key specifically designed with a better grip or a larger contact surface area. This can be particularly effective for slightly stripped screws.
- E-Z Out Screw Extractors: These are a commonly available and reliable option for removing stripped screws.
4. Drilling Out the Screw: The Last Resort
If all else fails, you may need to drill out the screw. This is a more destructive method, but sometimes necessary.
- Center Punch: Carefully center punch the screw head. This creates a starting point for your drill bit and helps prevent the bit from wandering.
- Drill Bit: Use a drill bit slightly smaller than the screw's core diameter. Drill slowly and carefully to avoid damaging the surrounding material.
- Screw Extractor for Broken Screws: Once you've drilled a pilot hole, you may be able to use a screw extractor designed for broken screws to remove the remaining material.
- Easy-Out: An alternative to a screw extractor is an Easy-Out. This tool works similarly to a screw extractor, but some find it more effective in some circumstances.
5. Using a Dremel Tool: For Precise Removal
A Dremel tool, with the right bits, can be used to carefully create slots or hex shapes to get a better grip. This method requires skill and precision, as improper use can damage the surrounding material.
Prevention: Tips for Avoiding Stripped Screws
- Use the Right Size Wrench: Always use an Allen wrench that perfectly fits the screw.
- Apply Lubricant: Use a lubricant before tightening screws to reduce friction.
- Avoid Excessive Force: Don't overtighten screws.
- High-Quality Tools: Invest in high-quality Allen wrenches made from durable materials.
By following these methods and preventative tips, you should be able to successfully remove even the most stubborn stripped Allen screw. Remember to choose the method best suited to the severity of the stripping and always prioritize safety.
