How to Remove a Stripped Allen Screw [15 Ways]

Imagine this: you’re working on a DIY project, and everything’s going smoothly until you encounter a stripped Allen screw. Frustrating, right? Don’t worry! In this comprehensive guide, we’ll teach you how to remove a stripped Allen screw, so you can get back to your project in no time. Stripped Allen screws are a common obstacle when working on various household items, automotive projects, or electronic devices, often due to overtightening, using an incorrectly sized Allen wrench, or simply through general wear and tear.

We understand that for DIY enthusiasts, overcoming challenges is part of the satisfaction in fixing things. That’s why we’ve put together this guide, which offers a variety of methods to tackle the issue of removing stripped Allen screws effectively and efficiently. By following our easy step-by-step process, you’ll be well-equipped to handle any stripped Allen screw situation that comes your way, and you’ll be an expert in no time.

How to Remove a Stripped Allen Screw: Step-by-Step Instructions

Follow these steps in order, as they increase in intensity. If a method doesn’t work, move on to the next one. Always remember that Allen screws open counter-clockwise.

1. Rubber Band or Paper Method

Tools Needed:

• Rubber band or a piece of paper
• Allen wrench
• Safety gloves for a good grip

Method:

This method involves using a rubber band or a piece of paper to provide extra grip between your Allen wrench and the stripped Allen screw. Position the rubber band or paper over the stripped Allen screw. Then, insert the appropriately sized Allen wrench over the paper or rubber band and exert pressure as you attempt to turn the screw counter-clockly. Ensure that you’re maintaining steady downward pressure to increase the chances of the wrench gripping the screw.

2. Upsize Your Allen Wrench

Tools Needed:

• Set of Allen wrenches in various sizes
• Safety gloves for a good grip

Method:

If the internal hex shape of the screw has widened (stripped), consider using the next larger size of Allen wrench. The idea here is that the slightly larger size might fit the stripped space more effectively, allowing you to turn the screw.

3. T-Handle Hex Wrench

Tools Needed:

• T-handle hex wrench
• Safety gloves for a good grip

Method:

Instead of using the standard L-shaped Allen wrench, consider switching to a T-handle hex wrench. The T-handle design provides a more substantial grip and allows you to apply more downward pressure, increasing your chances of turning the stripped screw.

4. Try a Torx Wrench

Tools Needed:

• Torx wrench set
• Safety gloves for a good grip

Method:

A Torx wrench, with its six-point star-shaped pattern, can sometimes fit better into a stripped Allen screw. The additional points of contact might provide a better grip than an Allen wrench. Ensure the Torx wrench is as close to the size of the screw as possible to avoid causing further damage.

5. Phillips Head Screwdriver to the Rescue

Tools Needed:

• Phillips head screwdriver
• Safety gloves for a good grip

Method:

If other tools aren’t helping, try using a Phillips head screwdriver. Insert the tip of the screwdriver carefully into the screw, then attempt to turn it. Do so gently to avoid further damaging or stripping the screw.

6. Screw-Grab Friction Liquid

Tools Needed:

• Screw-grab friction liquid
• Allen wrench
• Safety gloves to protect from the liquid
• Safety goggles to protect eyes

Method:

This specialty liquid is designed to increase the friction between the screw and the tool, thereby improving grip. Apply a small drop of this friction liquid to the top of the Allen screw, then insert your Allen wrench and try to turn the screw.

7. Needle-Nose Pliers

Tools Needed:

• Needle-nose pliers
• Safety gloves for a good grip

Method:

If any part of the Allen screw head is exposed, you can use needle-nose pliers to grip and turn it. Ensure you have a firm grip on the screw head and apply steady counter-clockwise pressure to remove the screw. You might find our guide on the best vise grips useful for handling such tools.

8. Apply Heat

Tools Needed:

• Small propane torch
• Allen wrench
• Heat-resistant safety gloves
• Safety goggles
• Flame-resistant clothing

Method:

If the material surrounding the screw is heat-resistant and not flammable, you can apply heat to the screw with a small propane torch. This heat can expand the screw, potentially breaking any rust or adhesion, making it easier to turn. Always exercise extreme caution when applying heat.

9. Use a Left-Hand Drill Bit

Tools Needed:

• Left-hand drill bit set
• Electric drill
• Safety gloves for a good grip
• Safety goggles to protect from flying debri

Method:

Choose a left-hand drill bit that is smaller than the screw’s diameter. Attach it to an electric drill set to reverse (counter-clockwise) rotation, then carefully drill into the screw. The counter-clockwise motion of the drill may help to turn the screw out.

10. Create a Groove for a Flat-Head Screwdriver

Tools Needed:

• Rotary tool with a metal cutting wheel
• Flat-head screwdriver
• Safety gloves for a good grip
• Safety goggles to protect from sparks and metal fragments

Method:

If you have a rotary tool with a metal cutting wheel, use it to cut a shallow groove into the head of the screw. This groove will accommodate a flat-head screwdriver, which you can then use to turn the screw out. Check out our comparison of die grinder vs. Dremel for more on rotary tools.

11. Utilize a Screw Extractor Kit

Tools Needed:

• Screw extractor kit
• Drill or manual T-shaped handle
• Safety gloves for a good grip
• Safety goggles to protect from flying debrisp

Method:

Screw extractor kits contain specially designed bits that can grip stripped screws. Choose a screw extractor bit from the kit that’s a bit smaller than the screw. Attach it to a drill or manual T-shaped handle, then carefully turn it counter-clockwise into the screw until the screw emerges.

12. Use a Two-Part Epoxy

Tools Needed:

• Two-part epoxy (resin and hardener)
• Allen wrench or T-shaped hex wrench
• Safety gloves to protect from the epoxy
• Safety goggles to protect eyes

Method:

In desperate cases, mix a two-part epoxy composed of resin and hardener. Select an Allen wrench or T-shaped hex wrench that fits the Allen screw as tightly as possible. Apply the mixed epoxy to the wrench and attach it firmly to the Allen screw. Allow the epoxy to cure fully, which may take up to 12 hours, before attempting to turn the screw out. This method is a last resort, as the epoxy will likely render the tool unusable for future tasks.

13. Hammer and Chisel Method

Tools Needed:

• Hammer
• Chisel
• Safety gloves for a good grip
• Safety goggles to protect from flying debris

Method:

If the screw head is raised and the material around it is sturdy, you could try using a small chisel and hammer. Place the chisel at the edge of the screw head and tap it gently with a hammer in a counter-clockwise direction. This method can damage the surrounding material, so use it with caution and only if other methods are not possible or successful.

14. Dremel and Cut-off Wheel

Tools Needed:

• Dremel tool or similar rotary tool
• Cut-off wheel
• Flat-head screwdriver
• Safety gloves for a good grip
• Safety goggles to protect from sparks and metal fragments

Method:

If you own a Dremel tool or another similar type of rotary tool, a cut-off wheel can be used to make a slot in the stripped screw. This new slot can then be used with a standard flathead screwdriver to unscrew it. Be sure to use a size of cut-off wheel that is appropriate for the size of your screw, and wear protective gear to shield yourself from sparks and metal fragments.

15. Welding a Nut to the Screw

Tools Needed:

• Welder
• Nut
• Wrench
• Welding helmet for eye and face protection
• Welding gloves for hand protection
• Flame-resistant clothing for body protection

Method:

This is an extreme method and should only be used if all other methods fail, and the material around the screw can withstand high heat. Using a welder, you can attach a nut to the stripped screw head. Once the welded nut has cooled down, you can use a standard wrench to turn the screw out. Remember to use appropriate protective equipment when welding.

FAQs:

Q: What is the best way to remove a stripped screw?

A: There are several ways to remove a stripped screw, but the best method depends on the specific situation. Some common methods include using a rubber band, employing a screw extractor kit, drilling the screw with a left-hand drill bit, or creating a groove for a flat-head screwdriver. Source: Popular Mechanics

Q: Can you use pliers to remove a stripped Allen screw?

A: You can use needle-nose pliers to remove a stripped Allen screw if a portion of the screw head is exposed, which will allow you to grip and turn the screw.

Q: How do you remove a stripped Allen screw from a faucet?

A: To remove a stripped Allen screw from a faucet, you can try using a rubber band, a larger Allen wrench, a T-handle hex wrench, a Torx wrench, a Phillips head screwdriver, needle-nose pliers, left-hand drill bits, or a screw extractor kit. It’s mportant to take extra care when working on a faucet to avoid damaging the surrounding components.

Time to Tackle Those Screws!

Removing stripped Allen screws can be a challenging task, but with the right tools and techniques, you can overcome this obstacle. By following the step-by-step guide provided above and utilizing our tips, you will be well-equipped to tackle any stripped Allen screw that comes your way. For those struggling with similar issues, but with bolts instead of Allen screws, our comprehensive guide on how to remove a stripped bolt offers useful tips and strategies. Remember to be patient and careful when attempting each method to avoid further damage to the screw or surrounding material. Good luck, and happy DIY-ing!

You might also like:

• 
  Mallet Vs Hammer: Differences and Use Cases
• 
  Top 5 Best Bench Vises (Buyers’ Guide)
• 
  Best Breaker Bar Reviewed: Expert Insights for DIY Enthusiasts