How To Remove A Stripped Allen Screw |10 Steps for Success

Q: How To Remove Stripped Allen Screw From Faucet Handle?

If the Allen screw is Remove stripped , it might be difficult or impossible to remove it. You might try using a vise grip or a wrench on the flats of the screw to try and turn it. If that doesn't work, you might try drilling the screw out. If you do drill it out, be careful not to damage the threads in the handle.

How To Remove A Stripped Allen Screw can be a frustrating experience, especially when it feels like the tool just won’t grip the screw head anymore. However, it’s a common issue, and with the right methods and tools, you can solve this problem efficiently. In this guide, we’ll take you through proven techniques to remove a stripped Allen screw. Whether you’re dealing with a tiny screw in a device or a larger one in a piece of furniture, these methods will help.

How To Remove A Stripped Allen Screw | Follow These 10 Easy Steps

1. Assess the Condition of the Stripped Allen Screw

Before diving into any removal methods, it’s important to assess how stripped the screw is. A screw may be partially stripped, meaning the Allen wrench still has some grip, or it may be completely stripped with no visible indentation for the tool. Knowing the condition will help you choose the most effective method.

Slightly Stripped: If the Allen wrench still grips the screw but slips occasionally, you may only need a simple method like using a better-fitting tool.
Severely Stripped: If the screw head is entirely worn down and no tool grips it, you’ll need more advanced techniques, which we’ll cover below.

2. Using a Rubber Band for Extra Grip

One of the simplest tricks to remove a slightly stripped Allen screw is to use a rubber band. This works when the screw is still partially intact and the tool just needs more grip.

Step 1: Place a wide rubber band (such as one from broccoli or produce) over the screw head.
Step 2: Insert the Allen wrench through the rubber band and into the screw head.
Step 3: Slowly and firmly turn the wrench. The rubber band will fill in the stripped areas of the screw and give the wrench extra grip.

3. Switch to a Different Tool Size

Allen screws are metric, meaning slight differences in sizes are common. If the standard-sized Allen wrench is slipping, try the next size up or down, as sometimes a slightly larger or smaller tool can grip the stripped head better.

Metric Example: If a 4 mm wrench is slipping, try a 4.5 mm or a 3.5 mm wrench.
Imperial Example: If you’re using a 3/16 inch wrench, switch to a 7/32 inch one.

This method is particularly useful if the screw isn’t severely stripped but just enough to cause slippage.

4. Apply Penetrating Oil

In some cases, the screw may be difficult to remove due to rust or corrosion, in addition to being stripped. Applying a penetrating oil like WD-40 can help loosen the screw, making removal easier.

Step 1: Spray a generous amount of penetrating oil onto the screw and let it sit for about 15-20 minutes.
Step 2: Attempt to remove the screw again using the Allen wrench. The oil will help lubricate and loosen the screw, making it easier to turn.

5. Use Pliers for Enhanced Grip

If the screw head is protruding from the surface, you can use pliers to get a firm grip on the head and twist it out. This method works best for larger screws where there’s enough surface to grip.

Step 1: Use locking pliers (e.g., Vise-Grip) for a strong grip on the screw head.
Step 2: Turn the pliers slowly to unscrew the stripped Allen screw.

For small screws or screws that are flush with the surface, this method won’t be effective.

6. Use a Screw Extractor Kit

A screw extractor kit is an essential tool for dealing with severely stripped screws. These kits come with specialized bits designed to grip the stripped head and twist it out.

Step 1: Drill a small pilot hole into the center of the stripped screw, making sure the hole is deep enough for the extractor to grip.
Step 2: Insert the screw extractor into the pilot hole and turn it counterclockwise. The extractor will dig into the screw and eventually remove it.

There are different types of screw extractors, including spiral flute extractors and straight flute extractors. Choose one based on your situation, but spiral flute extractors tend to work best for smaller Allen screws.

7. Use a Dremel or Rotary Tool

For severely stripped screws that cannot be removed by other methods, a rotary tool like a Dremel can be used to cut a new slot into the screw head.

Step 1: Use a cutting disc on the rotary tool to carefully cut a straight, deep slot into the screw head.
Step 2: Insert a flathead screwdriver into the new slot and twist it out.

This method should be used with caution, as cutting too deep can damage the surrounding material.

8. Heat the Screw

If penetrating oil didn’t work, applying heat to the screw can help loosen it. Heating expands the metal, which can break the bond between the screw and its threads.

Step 1: Use a heat gun or a soldering iron to apply heat directly to the screw.
Step 2: After heating for a minute or two, attempt to remove the screw with an Allen wrench or pliers.

Make sure you’re cautious when applying heat, especially if the screw is in plastic or heat-sensitive material. Heat is best used for metal applications where the surrounding material can handle the temperature increase.

9. Drill Out the Screw

Drilling out the screw is a last resort when all other methods fail. This technique is more destructive but guarantees screw removal.

Step 1: Choose a drill bit that is slightly smaller than the screw shaft.
Step 2: Carefully drill straight into the center of the screw. The goal is to remove the screw head without damaging the surrounding material.
Step 3: Once the head is drilled off, the rest of the screw can often be removed by hand or with pliers.

Use this method only when you’re prepared to potentially replace the screw and repair the surface.

10. Preventing Stripped Screws in the Future

To avoid the hassle of dealing with stripped Allen screws in the future, consider the following tips:

Use the Correct Size Tool: Always make sure to use the right size Allen wrench. A poorly fitting tool is one of the main causes of stripped screws.
Apply Steady Pressure: When turning the screw, apply steady, even pressure to prevent the tool from slipping.
Lubricate Screws Before Installation: A drop of oil on the threads before installation can prevent corrosion and make future removal easier.
Don’t Overtighten: Many stripped screws result from over-torquing. Tighten screws just enough to secure the component without forcing them.

Conclusion

Removing a stripped Allen screw doesn’t have to be a nightmare. With these 10 expert-approved methods, you’ll be able to tackle the problem effectively. From using a rubber band for extra grip to drilling out the screw as a last resort, these techniques cover every situation. Be patient, work methodically, and remember that prevention is always better than cure. Proper tools and Technique will save you from the frustration of stripped screws in the future.

See Also:

Frequently Asked Questions (FAQ)

How To Remove A Stripped Recessed Allen Screw?

There are a few ways to remove a stripped recessed Allen screw. One is to use a hex key or Allen wrench. Another is to use a drill bit. A third is to use needle-nose pliers.

How To Remove A Stripped Allen Screw From Crib?

There are a few ways to try to remove a stripped Allen screw from a crib. One way is to try to use a smaller Allen wrench to get a better grip on the screw head. Another way is to try to use a drill with a small drill bit to drill into the center of the screw head. Once the bit has penetrated the screw, you can try to use a screwdriver or a socket wrench to remove it.

How To Remove Allen Bolt Without Allen Key?

There are a few ways to remove an Allen bolt without an Allen key. One popular way is to use a vise grip. Another way is to use a screwdriver.

How To Remove Stripped Allen Screw From Faucet Handle?

If the Allen screw is Remove stripped, it might be difficult or impossible to remove it. You might try using a vise grip or a wrench on the flats of the screw to try and turn it. If that doesn’t work, you might try drilling the screw out. If you do drill it out, be careful not to damage the threads in the handle.