Removing a stripped Allen head screw can be incredibly frustrating, but with the right techniques and tools, it's often achievable without causing further damage. This guide provides a step-by-step approach, covering various methods to tackle this common problem. Whether you're a seasoned DIYer or a novice, this guide will equip you with the knowledge and strategies to conquer even the most stubborn stripped screws.
Understanding the Problem: Why Screws Strip
Before diving into solutions, let's understand why Allen head screws strip in the first place. Common causes include:
- Over-tightening: Applying excessive force during installation is a primary culprit.
- Damaged or worn tools: Using a worn or improperly sized Allen wrench can easily round off the screw head.
- Corrosion: Rust and other forms of corrosion can weaken the screw head and make it more susceptible to stripping.
- Material weakness: Some screws are simply made of softer metal, making them more prone to damage.
Methods for Removing Stripped Allen Head Screws
The best approach depends on the severity of the stripping and the accessibility of the screw. Here's a breakdown of effective methods, starting with the least invasive:
1. Improved Grip Techniques
Before resorting to more aggressive methods, try these:
- New Allen Wrench: Start with a fresh, correctly sized Allen wrench made of high-quality steel. A slightly larger wrench might offer a better grip in a minimally stripped screw.
- Apply Pressure Evenly: Avoid jerky movements. Apply steady, even pressure while turning.
- Penetrating Oil: Apply a penetrating oil like WD-40 or PB Blaster to the screw and let it soak for several minutes (or even longer). This can help loosen the screw and improve grip.
- Impact Driver: If you have an impact driver, the percussive force can sometimes help break loose a stubborn screw. Use a fresh, properly sized bit.
2. Using Specialized Tools
If simple methods fail, consider these specialized tools:
- Screw Extractor Set: Screw extractors are designed to grip stripped screws. Drill a pilot hole into the screw head, then carefully insert the extractor and turn counter-clockwise. Different sizes are available for various screw sizes. Caution: This method requires precision drilling to avoid damaging surrounding materials.
- Grip-Enhanced Bits: Some bit sets offer improved grip, often with aggressive gripping surfaces or coatings. These can provide better purchase on slightly stripped screws.
- Rubber Band/Vice Grip Method: Place a rubber band over the screw head before applying an Allen wrench. The rubber band can provide additional grip. Alternatively, carefully use a vice grip to clamp onto the screw head.
3. Destructive Methods (Use as a Last Resort)
If all else fails, these destructive methods might be necessary, but they often result in damage to the surrounding material:
- Drilling Out the Screw: As a last resort, you can carefully drill out the screw. This requires patience and precision to avoid damaging the surrounding material. You'll likely need a drill bit slightly smaller than the screw's diameter. After drilling, use a screw extractor or other methods to remove the remaining parts.
- Destroying the Head: In some cases, you can use a chisel or other sharp tool to carefully chip away at the screw head until it's loose enough to be removed with pliers. This is very risky and should only be considered if other options are impossible.
Prevention is Key
The best way to avoid the hassle of removing a stripped screw is to prevent it from happening in the first place. Remember to:
- Use the Correct Size Allen Wrench: Always use a properly sized wrench that fits snugly into the screw head.
- Avoid Over-Tightening: Tighten screws only to the required torque.
- Lubricate: Use lubricant during installation to prevent seizing.
- Maintain Your Tools: Regularly inspect your tools and replace worn or damaged ones.
By following these steps and employing the appropriate methods, you should be able to remove most stripped Allen head screws successfully. Remember to choose the method best suited to your situation and always prioritize safety and precision.
