Table of Contents

How to Get a Screw Out That Broke Off: A Comprehensive Guide

Dealing with a broken screw can be incredibly frustrating, whether you’re a seasoned DIY enthusiast or just tackling a simple home repair. A screw that snaps off leaves you with a stubborn piece of metal embedded in your project, potentially ruining your work and causing significant delays. Knowing how to get a screw out that broke off is a valuable skill that can save you time, money, and a whole lot of aggravation. This comprehensive guide will walk you through various techniques, tools, and tips to effectively remove a broken screw without causing further damage.

Understanding the Problem: Why Screws Break

Before diving into the solutions, it’s helpful to understand why screws break in the first place. Several factors can contribute to this common issue:

Over-tightening: Applying too much force when driving a screw is a primary culprit. The screw’s threads can strip, causing it to weaken and eventually snap.
Corrosion: Rust and corrosion weaken the metal, making the screw more susceptible to breakage. This is especially common in outdoor projects or areas with high humidity.
Material Fatigue: Repeated use and stress can cause metal fatigue, leading to a weakened screw that breaks under pressure.
Incorrect Screw Type: Using the wrong type of screw for the material can also cause problems. For example, using a wood screw in metal can lead to breakage.
Poor Quality Screws: Inexpensive or low-quality screws are often made from weaker metals and are more prone to breaking.

Essential Tools for Removing Broken Screws

Having the right tools on hand is crucial for successfully removing a broken screw. Here’s a list of essential tools you might need:

Screw Extractors (Screw Removal Kit): These specialized tools are designed to grip the broken screw and allow you to unscrew it. A good screw extractor kit is a must-have.
Drill: A drill is necessary for creating a pilot hole for the screw extractor. A variable-speed drill is ideal.
Drill Bits: You’ll need a variety of drill bits, including those recommended for use with your screw extractor kit.
Center Punch: A center punch helps create a starting point for your drill bit, preventing it from wandering.
Hammer: Use a hammer to tap the center punch and create the indentation.
Pliers (Needle-Nose or Locking Pliers): These can be helpful for gripping and turning small screw remnants.
Screwdrivers: A set of screwdrivers, including both Phillips head and flathead, will be useful for various tasks.
Penetrating Oil: Applying penetrating oil can help loosen corroded or stuck screws.
Heat Gun or Soldering Iron (Optional): Applying heat can sometimes help loosen a stubborn screw. Use with caution.
Rubber Bands or Steel Wool: These can sometimes improve grip if the screw head is stripped.

Methods for Removing a Broken Screw

Now, let’s explore the various methods you can use to get a screw out that broke off. The best approach will depend on the severity of the break, the type of material, and the tools you have available.

Using a Screw Extractor

A screw extractor is the most common and often the most effective method for removing a broken screw. Here’s how to use one:

Prepare the Area: Clean the area around the broken screw. If the screw is corroded, apply penetrating oil and let it sit for a few minutes.
Create a Pilot Hole: Use a center punch and hammer to create a small indentation in the center of the broken screw. This will help guide your drill bit.
Drill a Pilot Hole: Select a drill bit that is slightly smaller than the screw extractor. Carefully drill a pilot hole into the center of the broken screw. Keep the drill straight and apply steady pressure.
Insert the Screw Extractor: Insert the screw extractor into the pilot hole. Some screw extractors require you to tap them in with a hammer.
Turn the Screw Extractor: Using a wrench or pliers, slowly turn the screw extractor counterclockwise. Apply steady pressure and be patient. The extractor should grip the broken screw and begin to unscrew it.
Remove the Screw: Continue turning the screw extractor until the broken screw is completely removed.

Important Note: Screw extractors can be brittle and prone to breaking, especially if you apply too much force. Use caution and avoid over-tightening.

Using Pliers

If a portion of the screw is still protruding, you might be able to use pliers to grip and turn it. Needle-nose pliers or locking pliers are best for this method.

Grip the Screw: Firmly grip the protruding portion of the screw with the pliers.
Turn the Screw: Slowly turn the screw counterclockwise. Apply steady pressure and avoid stripping the screw further.
Remove the Screw: Continue turning until the screw is completely removed.

This method is most effective when the screw is not tightly embedded and a significant portion of it is still visible.

Using a Screwdriver and Rubber Band or Steel Wool

If the screw head is stripped but not completely broken off, you can try using a rubber band or steel wool to improve grip.

Place the Rubber Band or Steel Wool: Place a wide rubber band or a small piece of steel wool over the stripped screw head.
Insert the Screwdriver: Insert the appropriate screwdriver into the screw head, pressing down firmly. The rubber band or steel wool should help fill the gap and provide better grip.
Turn the Screwdriver: Slowly turn the screwdriver counterclockwise. Apply steady pressure and avoid stripping the screw further.
Remove the Screw: Continue turning until the screw is completely removed.

This method works best when the screw is not too tightly embedded and the stripping is not too severe.

Using Heat

Applying heat can help loosen a stubborn screw by expanding the surrounding material. This method should be used with caution, as it can damage certain materials.

Apply Heat: Use a heat gun or soldering iron to apply heat to the area around the broken screw. Be careful not to overheat the material.
Let it Cool: Allow the area to cool slightly.
Try Removing the Screw: Use one of the methods described above (screw extractor, pliers, etc.) to try removing the screw.

Heat can be particularly effective for screws that are corroded or stuck due to adhesive.

Drilling Out the Screw (Last Resort)

If all other methods fail, you may need to drill out the screw completely. This method should be used as a last resort, as it can damage the surrounding material.

Select a Drill Bit: Choose a drill bit that is slightly smaller than the diameter of the screw.
Drill Out the Screw: Carefully drill into the center of the broken screw. Start slowly and gradually increase the speed. Keep the drill straight and apply steady pressure.
Remove the Remnants: Once you’ve drilled through the screw, you may need to use a small screwdriver or pick to remove any remaining pieces.

This method will likely destroy the screw threads, so you’ll need to use a new screw or consider repairing the hole.

Preventing Screws from Breaking in the Future

Prevention is always better than cure. Here are some tips to help prevent screws from breaking in the future:

Use the Right Screw Type: Choose the appropriate screw type for the material you’re working with.
Avoid Over-Tightening: Be careful not to over-tighten screws. Use a drill with adjustable torque settings.
Apply Lubricant: Use a lubricant, such as wax or soap, on the screw threads to reduce friction.
Pre-Drill Pilot Holes: Always pre-drill pilot holes, especially when working with hardwoods.
Use High-Quality Screws: Invest in high-quality screws made from durable materials.
Inspect for Corrosion: Regularly inspect screws for signs of corrosion and replace them as needed.

Conclusion

Knowing how to get a screw out that broke off is a valuable skill for any DIYer or homeowner. By understanding the causes of screw breakage and mastering the various removal techniques, you can tackle this common problem with confidence. Remember to use the right tools, apply steady pressure, and be patient. With a little practice, you’ll be able to remove even the most stubborn broken screws without causing further damage. If you’ve tried all the above and still can’t get a screw out that broke off, consider calling a professional. [See also: Repairing Stripped Screw Holes] [See also: Best Drill Bits for Metal] [See also: Choosing the Right Screwdriver]