How To Get Out A Broken Screw In Metal

How to Get Out a Broken Screw in Metal: A Comprehensive Guide

Removing a broken screw from metal can be frustrating, but with the right tools and techniques, it's entirely achievable. This guide covers various methods, from simple solutions to more advanced techniques, ensuring you can tackle this common problem effectively. Whether you're a seasoned DIY enthusiast or a novice, this article provides step-by-step instructions to help you extract that stubborn screw.

Assessing the Situation: Understanding the Challenge

Before diving into solutions, assess the severity of the broken screw. Consider these factors:

• How much of the screw is sticking out? A larger portion is easier to grip.
• Is the screw head damaged significantly? Extensive damage might require more aggressive techniques.
• What type of metal is involved? Softer metals might be more susceptible to damage during removal.
• What tools do you have available? Having the right tools will greatly simplify the process.

Simple Solutions: For Minor Breakage

For screws with a slightly damaged head, or where a portion of the screw remains, these methods often suffice:

• Using a Screw Extractor: This specialized tool has reverse-threaded bits that grip the broken screw and unscrew it. Choose a size slightly smaller than the broken screw. Drill a pilot hole carefully into the center of the broken screw, then insert the extractor and turn counter-clockwise.

• Applying Extra Grip with Pliers or Vice Grips: If enough of the screw head protrudes, carefully use pliers or vice grips to grip the remaining screw head firmly and turn it counter-clockwise. Be cautious not to strip the screw head further. Consider using a rubber grip on the pliers for better traction and to protect the surrounding metal.

• Using a Rubber Band: Place a rubber band over the damaged screw head, creating a better grip for your screwdriver. This simple trick provides increased friction and can help prevent slippage.

Advanced Techniques: For Severely Damaged Screws

When the screw head is significantly damaged or completely broken off, more advanced methods are required:

• Drilling and Extracting: This involves carefully drilling a small pilot hole into the center of the broken screw, using a drill bit slightly smaller than the screw's diameter. Then, use a screw extractor or a left-handed drill bit to remove the screw. Proceed slowly and carefully to avoid damaging the surrounding metal.

• Using a Dremel Tool with a Cutting Disk: For very stubborn screws, a Dremel tool with a thin cutting disk can create slots to allow for the use of a flat-head screwdriver. Be extremely cautious when using a Dremel tool, as it's easy to damage the surrounding metal. Use light pressure and make multiple passes.

• Welding a Nut to the Broken Screw: This method involves welding a nut onto the remaining screw. Once cooled, you can use a wrench to remove the screw. Requires welding equipment and skills. This is a more involved process and might require professional assistance.

Preventing Future Problems: Best Practices

• Use the correct screwdriver: Match the screwdriver to the screw head type to avoid damaging it.
• Apply Lubricant: A lubricant like WD-40 can help prevent stripping and ease removal.
• Avoid over-tightening: Tighten screws firmly but not excessively.
• Proper Tool Usage: Always use the appropriate tool for the job and use caution when applying force.

By following these steps and choosing the appropriate method, you can successfully remove a broken screw from metal. Remember to exercise patience and proceed carefully to avoid further damage. If you're unsure about any step, it's always best to seek professional assistance.