Dealing with a stripped Allen screw is frustrating, but don't despair! This comprehensive guide provides multiple solutions to remove that stubborn screw, ranging from simple fixes to more advanced techniques. We'll cover everything from preventing future stripping to the best tools for the job. Knowing how to get out a stripped Allen screw is a valuable skill for any DIY enthusiast or professional.
Understanding the Problem: Why Allen Screws Strip
Allen screws, also known as hex keys or socket head cap screws, are popular due to their strength and compact design. However, their relatively small head size makes them prone to stripping if over-torqued or if the wrong tool is used. Several factors contribute to stripped Allen screws:
- Incorrect Tool Size: Using a slightly too small Allen wrench can cause the edges to dig into the screw head, leading to stripping.
- Over-Torquing: Applying excessive force when tightening or loosening a screw can easily damage the head.
- Damaged or Worn Allen Wrench: A worn or damaged Allen wrench will not grip the screw properly, causing slippage and potential stripping.
- Material Degradation: Over time, screws can become corroded or weakened, making them more susceptible to stripping.
- Low-Quality Screws: Some screws are made from softer metals, making them more prone to damage.
Preventing Stripped Screws: Using the correct size Allen wrench and applying the right amount of torque are crucial for preventing stripped screws. Always use a high-quality, well-maintained wrench and avoid using excessive force. Consider using a torque wrench for precise control, particularly with critical applications.
Methods to Remove a Stripped Allen Screw
The best approach depends on the severity of the stripping and the accessibility of the screw. Here are several proven methods:
1. Using a Larger Allen Wrench (For Minor Stripping):
If the stripping is minimal, try using a slightly larger Allen wrench. This sometimes provides enough grip to loosen the screw. Apply even pressure to avoid further damage. Caution: This method only works for minor stripping.
2. Applying Penetrating Oil:
Penetrating oil, like PB Blaster or WD-40, can help loosen a stubborn screw. Apply generously to the screw head and let it sit for several minutes, or even overnight, to penetrate the threads and break down any corrosion. After application, attempt to remove the screw with the correct size Allen wrench.
3. Using a Rubber Band or Grip Pad:
Placing a rubber band between the Allen wrench and the screw head can provide extra grip, particularly on slightly stripped screws. Similarly, adhesive grip pads can create more friction, helping you remove the screw.
4. Employing an Allen Wrench with a Magnetic Tip:
Magnetic tips on Allen wrenches can provide improved grip and prevent the wrench from slipping. This is particularly helpful when dealing with stripped or slightly corroded screws.
5. Utilizing Screw Extractors:
Screw extractors are specialized tools designed to remove stripped screws. They are available in various sizes and types, including:
- Easy-Outs: These are tapered drill bits with reverse threads that grab into the stripped screw. Drill a pilot hole in the center of the screw head, then carefully screw the extractor into the hole and turn counter-clockwise.
- Screw Extractor Sets: These sets often include several different sizes of extractors to handle a range of screw sizes and stripping severity.
Using a Screw Extractor - A Step-by-Step Guide:
- Drill a pilot hole: Carefully drill a pilot hole of the appropriate size into the center of the stripped screw head. The hole should be slightly smaller than the extractor's diameter.
- Insert the extractor: Gently screw the extractor into the pilot hole.
- Apply counter-clockwise pressure: Gradually apply counter-clockwise pressure to remove the screw. Avoid excessive force, which could damage the extractor or the surrounding material.
- If resistance is met, carefully add penetrating oil.
Caution: Screw extractors can be challenging to use and require patience. If you are unsure, it's best to consult a professional.
6. Drilling Out the Screw:
As a last resort, the screw head can be drilled out. This requires precision and care to avoid damaging the surrounding material. Use a drill bit slightly smaller than the screw's diameter, then carefully drill the screw head until it's removed. After removing the head, try to use a screw extractor on the remaining shaft, or alternatively, remove the screw from the opposite side.
Caution: This method is destructive and should only be used as a last resort. It may leave a hole that requires repair or replacement.
Case Study: Stripped Screw in a Valuable Piece of Furniture
Imagine a stripped screw on an antique table. Using a screw extractor would likely damage the finish. In this case, the best option might be to apply penetrating oil, let it soak overnight, and then carefully try to remove the screw using a slightly larger Allen wrench, or utilize the rubber band technique. If that fails, a professional furniture restorer might be the best option to prevent any further damage.
Choosing the Right Tools: Quality Makes a Difference
Using high-quality tools is crucial for preventing stripped screws and successfully removing them. Invest in a good set of Allen wrenches in various sizes. Look for wrenches made from hardened steel, which are more durable and less likely to bend or break. A torque wrench is also recommended for critical applications.
Conclusion: Preventing Future Stripped Screws
By carefully selecting the correct sized Allen wrench and applying appropriate torque, along with using penetrating oil as a preventative measure, you can greatly reduce the chances of facing a stripped Allen screw again. However, by following the steps outlined in this guide, you're well-equipped to handle this common problem. Remember to always start with the least destructive method and only progress to more drastic measures if necessary.