Few things are as frustrating as a broken screw stuck deep in metal, bringing your project to a screeching halt. Whether you’re fixing furniture or tinkering with machinery, a stubborn snapped screw can seem impossible to remove.
This common problem is more than just an annoyance—it can make repairs difficult or even force you to start over. In this article, you’ll find simple, effective steps and tips for safely extracting a broken screw from metal, so you can get back to work.
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How to Get a Broken Screw Out of Metal: Step-by-Step Guide
Dealing with a broken screw lodged in metal can feel frustrating. But with the right tools, techniques, and a bit of patience, you can remove even the most stubborn broken screw and restore your project to its former glory. Below, discover a detailed guide on tackling this common problem, easy-to-follow steps, and practical advice for success.
Why Removing a Broken Screw is Tricky
When a screw head snaps off or the body is stripped, you lose the ability to simply unscrew it. This usually happens due to:
- Excessive force when tightening.
- Old, rusted, or weakened screws.
- Using the wrong screwdriver size or type.
- Overtightening or cross-threading.
The problem is more challenging in metal because the screw often grips tightly, especially if rust or corrosion is involved. But don’t worry! With careful action, you can get the job done.
10 Proven Methods to Remove a Broken Screw from Metal
There are several methods, each suited to different situations. Here’s a breakdown of the most effective ways:
1. Use a Screw Extractor
Screw extractors are specifically designed for removing broken or stripped screws.
How to Use:
- Drill a Pilot Hole:
Use a small drill bit to carefully drill into the center of the broken screw. This creates a hole for the extractor to grip. - Insert Extractor:
Place the screw extractor into the pilot hole. - Twist Counterclockwise:
Turn the extractor using a T-handle or adjustable wrench. The extractor’s reverse-threaded design bites into the screw and unscrews it as you turn.
Benefits:
– Highly effective for broken screws where the head is missing.
– Works on many types of metal.
Tips:
– Use lubricant (like WD-40) to ease removal.
– Go slowly to avoid breaking the extractor.
2. Drill Out the Broken Screw
If the extractor method fails or you don’t have an extractor, you can drill the screw completely out.
How to Drill Out a Screw:
- Select a Drill Bit:
Choose a bit slightly smaller than the screw’s diameter. - Drill Slowly:
Apply steady pressure and low speed to prevent breaking the drill bit. - Remove Debris:
Clear out metal shavings as you go. - Retap Threads (if needed):
Use a tap to restore the hole’s threads, or fit a slightly larger screw.
Challenges:
– Can enlarge the hole, requiring thread repair.
– Generates heat—avoid prolonged drilling.
3. Use Pliers or Vice Grips
If part of the screw protrudes from the metal, try gripping it.
How to Remove with Pliers:
- Grip Tightly:
Clamp locking pliers or vice grips firmly onto the broken screw. - Twist Gently:
Rotate counterclockwise to back the screw out.
Tip:
If the screw is stuck, add penetrating oil and give it time to seep in.
4. Apply Heat
Heat can loosen rusted or thread-locked screws.
How to Use Heat:
- Heat the Metal:
Use a heat gun or soldering iron to warm the area around the screw (not the screw directly). - Try Extracting Again:
Once the metal heats and expands, use pliers or an extractor.
Important:
Avoid open flame, especially near flammable materials or finishes.
5. Tap with a Hammer and Punch
A sharp jolt can loosen a stubborn screw.
How To:
- Place a Center Punch:
Set it in the center of the broken screw. - Tap Lightly:
Hit with a hammer several times. - Attempt Removal:
Try to grip with pliers or use an extractor.
6. Weld a Nut to the Broken Screw
If you have access to welding tools and the screw is large enough:
- Weld a Nut On Top:
Weld a nut to the exposed surface of the screw. - Use a Wrench:
Twist the nut, and the screw will come with it.
Note:
This works best for larger or industrial screws and requires welding skills.
7. Use Left-Handed Drill Bits
Left-handed bits unscrew as they drill.
How It Works:
- As you drill into the screw, the left-handed action may catch and unscrew it.
- Especially useful if the screw broke due to overtightening.
8. Cut a New Slot
If you can see part of the screw, use a rotary tool.
- Make a Straight Slot:
Use a Dremel or cutting disc to cut a new slot across the screw. - Use a Flathead Screwdriver:
Try unscrewing it with a standard driver.
9. Chemical Methods
For rusted screws:
- Apply a rust dissolver or WD-40.
- Allow it to soak in (up to several hours if heavily rusted).
- Proceed with pliers or extractor.
10. Tap and Twist Method
- Tap Around the Screw:
Use a punch or old screwdriver and hammer to gently tap the screw counterclockwise. - Repeat Until Loose:
Once it starts moving, switch to pliers or extractor.
Step-by-Step Basic Extraction Process
Let’s put the above into a simple, actionable checklist.
- Assess the Situation:
See if any screw is protruding. - Apply Lubricant:
Give it time to penetrate. - Attempt Pliers Removal:
Always try the simplest method first. - Drill a Pilot Hole:
Center the hole carefully if needed. - Try a Screw Extractor:
Use slow, steady force. - Drill Out as Last Resort:
Only after all else fails.
Tips and Best Practices
- Safety First:
Always wear safety glasses to protect your eyes from metal shavings. - Work Slowly:
Rushing can break tools or further damage threads. - Pick the Right Tools:
Use good-quality extractors or bits—cheap ones may snap. - Use the Correct Drill Bit Size:
Too large can ruin threads; too small may break off in the screw. - If Using Power Tools:
Maintain a firm grip and low speed.
Cost-Saving Advice
- Tool Kits:
A screw extractor set is a handy, relatively low-cost investment—much cheaper than hiring a pro or replacing parts. - Reuse and Restore:
Remove and clean screws (when possible) for small repairs to save money. - Shipping Tips:
Order tools online from reputable retailers to take advantage of free shipping offers, or purchase locally to save on shipping costs. - DIY Over Repair Shops:
Trying it yourself first can save substantial labor costs.
Challenges and How to Overcome Them
- Extractor or Drill Bit Breaks:
Go slow, avoid using dull bits, and don’t force the tool. - Metal Deformation:
Use proper drill speeds and lubricants to prevent overheating and warping. - Old or Rusty Screws:
Allow extra penetration time for lubricants and rust dissolvers.
When to Seek Professional Help
If the screw remains stuck after several attempts, the surrounding metal is valuable or delicate, or precision is critical (e.g., automotive, electronics), it’s best to consult a technician or machinist. They have specialized equipment and experience for these high-stakes extractions.
Summary
Removing a broken screw from metal can be a straightforward DIY task if you use the right approach:
- Start simple, with pliers or lubricant.
- Move up to extractors or drilling if needed.
- Take your time, use proper safety gear, and don’t rush.
- For difficult cases, consider professional help to avoid accidental damage.
With a bit of patience, you’ll have that stubborn screw out and your metal project back on track!
Frequently Asked Questions (FAQs)
1. How can I prevent breaking screws in the future?
To avoid broken screws, always use the correct screwdriver size, avoid overtightening, and lubricate screws when working with hard metals. Replace old or corroded screws instead of forcing them.
2. What should I do if my screw extractor breaks inside the screw?
Extractor bits are hardened and difficult to remove. If one breaks off inside the screw, try using masonry drill bits to drill around or through. If that fails, you may need professional help or to enlarge and re-tap the hole.
3. Is it safe to use heat on metal to remove a stuck screw?
Generally, yes—applying moderate heat can expand the metal and free the screw. Avoid very high temperatures and open flames that can damage finishes or ignite surrounding materials.
4. Can I reuse the existing hole after removing a broken screw?
Yes, if the threads aren’t damaged, you can reuse the hole. If threads are stripped, use a thread repair kit, insert, or a slightly larger screw to restore hold.
5. What if the broken screw is completely flush or below the metal surface?
When a screw is flush or below the surface, use a center punch to create a depression for your drill bit, then proceed with drilling and extraction as described above. Special extractor kits are designed for below-surface removals.
By following these steps, tips, and safety practices, you’ll become much more confident at tackling broken screws in metal—saving time, money, and frustration every time a stubborn fastener stands in your way!