Few things are more frustrating than discovering a screw snapped off and stuck in metal right when you need a quick fix. Whether you’re dealing with home repairs, car maintenance, or a DIY project, a broken screw can bring everything to a standstill.
Knowing how to remove a broken screw is essential for saving time, money, and headaches. In this article, you’ll find straightforward steps, practical tips, and expert insights to tackle this common challenge with confidence.
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How to Remove a Broken Screw in Metal: Step-by-Step Guide
Removing a broken screw in metal might seem intimidating at first, but with the right approach, tools, and a little patience, it is achievable by most DIYers. Whether you’re dealing with a snapped screw whose head has sheared off or a stubborn, rusted fastener lodged in metal, there are proven methods to tackle the problem. This guide will walk you through the complete process, offer practical tips, and answer your most pressing questions.
Understanding the Challenge: Why Screws Break in Metal
Screws can break or become stuck in metal for several reasons:
- Overtightening during installation.
- Corrosion or rust, especially in outdoor or moist environments.
- Old hardware that has weakened over time.
- Using the wrong type of screw or tool for the material.
When a screw breaks, it may leave behind a jagged piece above the surface or bury itself flush—or even below—the metal, making removal more complex.
Step-By-Step Removal Methods
Let’s break down several effective techniques, from the simplest to some requiring specialized tools. Pick the solution that fits your situation best.
1. Assess the Situation
Before you reach for tools, inspect the broken screw:
- Is any part sticking out above the metal?
- Is it flush or recessed?
- Is the metal around it damaged?
- Is rust or corrosion visible?
This will dictate your removal method.
2. Easy Out: Grab What’s Left
If part of the screw still extends above the surface, try these:
Pliers or Vice Grips
- Grip the exposed screw securely.
- Slowly turn counterclockwise. Don’t force it—work gently to avoid snapping it further.
Flathead Screwdriver Tip
- If a bit of the screw’s shaft is above the surface, press a flathead screwdriver into any available groove or edge.
- Turn gently to unscrew.
3. Creating a Slot
Sometimes you must make your own grip:
- Take a rotary tool (such as a Dremel) fitted with a cutting wheel.
- Cut a groove into the exposed shaft of the broken screw, turning it into a sort of “makeshift slot head.”
- Fit a flathead screwdriver into the new slot and turn counterclockwise.
This is especially effective for screws partially above the surface.
4. Drilling a Pilot Hole
If the screw is stuck, flush, or below the surface:
-
Center Punch
Place a center punch at the screw’s center and lightly tap it with a hammer. This will stop your drill bit from wandering and help ensure accuracy. -
Drill a Small Hole
Using a bit slightly smaller than the screw’s diameter, drill straight into the center of the broken fastener. Go slowly, ensuring you remain straight.
Tip: Use a sharp, high-speed steel (HSS) drill bit for metal, and consider applying oil to lubricate and cool the bit during drilling.
5. Screw Extractor (Easy-Out) Method
Once you’ve drilled a pilot hole, grab a screw extractor kit (often called “Easy-Out” extractors):
- Insert the extractor’s tip into your pilot hole.
- Turn the extractor counterclockwise using its handle or a tap wrench. As you turn, its flutes bite into the metal and grip the screw.
- Continue slowly—steady, firm pressure works best.
Benefits of this Method:
– Designed for broken/stripped screws.
– Reduces risk of further damage to the metal.
6. Drilling Out the Screw Entirely
If a screw extractor fails:
- Use a drill bit slightly smaller than the screw’s outer threads.
- Carefully drill all the way through the screw.
- Clean out any loose material with a pick or compressed air.
You may be able to retap the hole or use a slightly larger screw if needed.
7. Using Chemical Penetrants
For rusted or corroded screws:
- Apply penetrating oil (WD-40 or similar) liberally to the screw.
- Let it soak in for 15-20 minutes, or longer for severely rusted screws.
- Try loosening with pliers or a screwdriver.
Tip: This is best for screws that are stuck but still have some exposed material.
8. Using Heat
Caution: Use care if working with flammable materials!
- Gently heat the metal around the screw with a heat gun or propane torch for a few minutes.
- The expansion and contraction can often break the metal-to-screw bond.
- Try removal again once it has cooled a bit.
9. Welding a Nut
For those with welding experience:
- Tack-weld a nut to the top of the broken screw.
- Once cooled, use a wrench to unscrew the nut—and the broken fastener should come out with it.
10. Tapping New Threads
If removal damages the original threads:
- Use a tap of the correct size to re-thread the hole.
- Alternatively, insert a threaded insert (like a Helicoil) to restore the hole’s integrity.
Practical Tips and Best Practices
- Work Slowly: Rushing increases the risk of further breakage or damaging the surrounding material.
- Use the Right Tools: High-quality extractors, sharp drill bits, and sturdy pliers make the job faster and safer.
- Lubricate Often: Drilling through metal generates friction and heat. A drop of oil protects both bit and workpiece.
- Protect the Metal Surface: Place painter’s tape around the work area to avoid accidental scratches.
- Stay Centered: Always drill as close to the dead center of the screw as possible to avoid damaging existing threads.
Common Challenges and How to Overcome Them
Stripped Screws
If a screw is stripped (the drive head is rounded or mangled):
- Try rubber band trick: Place a wide rubber band over the stripped head, then push the screwdriver through it for better grip.
- Use a screw extractor or drill out as described above.
Hardened Steel Screws
Some screws, especially in machinery, are extremely tough:
- Go slowly with drilling—and only use cobalt or titanium-coated bits designed for hardened steel.
Rust and Corrosion
Deep rust can mean traditional methods won’t work:
- Soak repeatedly with penetrant.
- Alternate heat and cold to break up rust bonds.
Cost-Saving Tips
- Basic Tools: Many of the above methods use common tools (pliers, hammers, drill, screwdriver), which most DIYers own.
- Screw Extractor Kits: Modestly priced at hardware stores, and reusable.
- Professional Help: If you don’t feel confident—or if the screw is in expensive or sensitive equipment—consider a professional. Often, shops charge by the job, not by the hour, especially if you bring the part to them.
- Avoid Further Damage: Take your time. Rushing may lead to a ruined workpiece, which is much more expensive than any extractor tool.
Shipping Parts: If waiting for new screws or extractor kits via shipping, standard ground shipping is usually cheapest. Buying in bulk (even for future projects) can cut costs per item.
Summary
Removing a broken screw from metal might look daunting but can be tackled step-by-step with the right strategy. Always start with the simplest solution, like gripping what’s left with pliers, before advancing to drilling, extractors, or specialty solutions like welding. Patience, the right tools, and a steady hand protect both your metalwork and your wallet.
Frequently Asked Questions (FAQs)
1. What is the best way to remove a screw that is broken flush with the metal surface?
When a screw breaks and sits flush (or just below) the metal, the best approach is to drill a small pilot hole in its center and use a screw extractor. These tools are specially designed to grip and remove broken fasteners that other methods can’t reach.
2. Can I remove a broken screw without a drill or extractor?
If part of the screw is sticking out, you may succeed with sturdy pliers or locking vice grips. Creating a new slot using a rotary tool and then turning the screw out with a flathead driver is another option. However, if the screw is flush or recessed, a drill and extractor are usually necessary.
3. How can I prevent screws from breaking in the future?
Always use the correct type and size of screw for the material, avoid overtightening, and apply a small amount of lubricant or anti-seize compound to screws in metal. This reduces friction and helps protect against corrosion, especially in outdoor or humid settings.
4. What should I do if the threads in the metal are damaged after removing the screw?
If the threads are stripped or worn, you can restore them using a tap of the correct size or by installing a threaded insert such as a Helicoil. This will allow you to reuse the hole with a new screw and maintain the structural integrity of your project.
5. Is it better to try removing a broken screw myself, or should I hire a professional?
Most straightforward cases can be tackled by DIYers with patience and the right tools. However, if the screw is in expensive or delicate equipment, or you feel unsure about drilling and extracting, it may be best to consult a professional. Avoiding further damage can save time and money in the long run.