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Allen screws are commonly used fasteners with a hexagonal indentation in the center, which allows them to be tightened or loosened with an Allen wrench (hex key). However, there are times when the Allen screw becomes stripped, making it nearly impossible to unscrew using the usual method. A stripped Allen screw occurs when the hexagonal recess is damaged, either by excessive force, wear, or an improperly fitting wrench. In these cases, it becomes necessary to use alternative methods to remove the screw. This article provides an in-depth guide on how to unscrew a stripped Allen screw.
Before diving into the solutions, it's essential to understand what causes an Allen screw to become stripped. Typically, the screw gets stripped when the wrench or key slips out of the socket or fails to fit properly into the screw’s hexagonal recess. Over time, repeated use or excessive pressure can cause the edges of the hexagonal shape to wear down, leaving the screw surface smooth and difficult to grip.
Once the Allen screw is stripped, traditional methods of using an Allen wrench will not work, and you may need to consider more specialized techniques.
There are several ways to approach the task of unscrewing a stripped Allen screw, and each method comes with its own set of tools. Below is a breakdown of the most effective techniques.
If the screw is only partially stripped and there’s still some grip left in the hexagonal recess, you might want to try using a slightly larger Allen wrench. A wrench that fits more snugly can provide the necessary grip to turn the screw.
Select a slightly larger Allen wrench than the one you used originally.
Insert the wrench into the hexagonal recess of the stripped screw.
Apply firm, consistent pressure while turning the wrench counterclockwise.
This method works best if only the edges of the recess are worn down, allowing a snug fit with a new wrench.
For particularly stubborn or corroded screws, applying penetrating oil can help loosen the screw and make it easier to remove. Penetrating oils, such as WD-40, work by breaking down rust and reducing friction, making the screw easier to unscrew.
Spray a generous amount of penetrating oil onto the stripped screw.
Allow the oil to sit for at least 10–15 minutes. For tough cases, let it sit overnight.
Try using the Allen wrench again after the oil has had time to penetrate the screw.
This method is most effective when dealing with rusted or corroded screws but may not work for screws that are stripped due to wear or abuse.
A simple and inexpensive solution is using a rubber band to create more friction between the Allen wrench and the stripped screw. The rubber band can help fill in the gaps in the stripped screw recess, providing extra grip to unscrew it.
Place a rubber band over the stripped Allen screw.
Insert the correct size Allen wrench into the recess, pressing it against the rubber band.
Slowly turn the wrench counterclockwise.
This method is particularly effective if the stripped screw is not too severely damaged.
A screw extractor kit is a specialized tool designed specifically for removing stripped screws. These kits contain bits that can grip the damaged screw head and turn it with increased torque. There are various types of screw extractors, including those that work by drilling into the center of the screw.
Choose the appropriate screw extractor bit size that fits into the stripped recess.
Drill a small pilot hole in the center of the stripped screw using a drill bit from the extractor kit.
Insert the screw extractor into the pilot hole.
Use a wrench to turn the extractor counterclockwise and remove the screw.
This is one of the most effective ways to deal with stubborn or completely stripped screws.
If the screw head is raised enough, you may be able to grip it with a pair of locking pliers (such as Vise-Grips). By gripping the outer edges of the screw head, you can apply enough force to unscrew it.
Clamp the locking pliers onto the edges of the stripped screw head.
Turn the pliers counterclockwise while applying firm, steady pressure.
This method works best when the screw is only slightly stripped and still has enough surface area to grip.
If the screw is severely stripped and no other method works, drilling out the screw is the last resort. Drilling out the screw requires the use of a drill and the right size bit to remove the screw completely. While this method is effective, it does result in the destruction of the screw.
Choose a drill bit that matches the diameter of the screw or is slightly smaller.
Drill into the center of the stripped screw until the head is removed or the screw is loosened enough to be pulled out.
Once the head is removed, you can either pull the remaining shaft out or continue drilling to remove the entire screw.
If the stripped Allen screw is still slightly protruding above the surface, you can use a hammer and chisel to tap the edges of the screw and create new grip points. This can be a time-consuming and labor-intensive process but is sometimes effective for getting a grip on difficult screws.
Position the chisel at an angle to the edge of the screw head.
Tap the chisel with a hammer to gently rotate the screw.
Continue tapping and rotating until the screw is loose enough to remove with your hands or pliers.
If you have access to a welder, you can weld a nut to the stripped screw. This method is highly effective for removing screws that are too damaged to grip with any other tool. By welding the nut to the screw, you create a new surface to which you can attach a wrench.
Place a nut over the stripped screw.
Weld the nut to the screw using a welder.
Once the nut is welded, use a wrench to unscrew the nut and remove the screw.
This method is typically used in industrial settings or when the screw is in a particularly difficult position.
If your Allen wrench is slipping, it may be because it’s too small for the screw’s recess. Try using a slightly larger wrench, or apply a rubber band for additional grip. In some cases, a screw extractor may be necessary.
Yes, depending on the method you use. Methods like using a rubber band, pliers, or a different size Allen wrench are gentle and may not damage the surrounding surface. However, using a drill or welding may cause more damage.
To prevent stripping, ensure that you are using the correct size Allen wrench for the screw. Apply consistent, controlled force, and avoid using too much torque, which can cause the recess to wear down.
If the stripped screw is in a tight spot, you may need to use specialized tools like flexible drill extensions or right-angle wrenches. Alternatively, you could try the rubber band method to add extra grip without needing much space.
Yes, after successfully removing a stripped Allen screw, you can replace it with a new one of the same size and thread type. Make sure to check that the new screw fits properly to avoid similar issues in the future.
Dealing with a stripped Allen screw can be frustrating, but there are numerous methods you can use to unscrew it effectively. Whether you choose to use a different size Allen wrench, apply penetrating oil, or use a screw extractor kit, the key is to find the method that works best for your specific situation. Remember, prevention is better than cure, so always use the right tools and apply appropriate torque when tightening Allen screws to avoid future stripping. With the right techniques, you’ll be able to handle even the most stubborn screws with ease.
