How to Remove a Stripped Allen Screw – in 8 Easy Ways

Suppose you are engrossed in your next drive, and you stumble upon a stripped Allen screw. Things will remain messed up until you figure out how to remove that stripped Allen screw without messing up its surroundings. Annoying, right?

You need to know how to remove a stripped Allen screw to continue. It might look tricky, but it is an easy task if you know what you are doing.

This guide will teach you how to remove that Allen screw easily. Let us discuss some of these methods and find your ideal solution.

How Do Allen Screws Get Stripped?

It is better to be safe than sorry. Along with knowing how to remove a stripped Allen screw, you need to know how you can prevent the screw from getting stripped in the first place.

Screws often get stripped over time. In most cases, screws get stripped when you leave them alone for too long without much care.

Screws can start rusting at any time. Rust can appear more quickly if the screws are left outside or exposed to moisture. Unless you monitor the screws regularly, there is a high chance you will end up with stripped Allen screws in no time.

Always use the right tools. The tool you use to remove problematic Allen screws should match the screw perfectly. Do not use mismatched flat screwdrivers or drills. Make sure the driver is fully seated before inserting the screw.

A lot of friction occurs when inserting and removing Allen screws with flat-head screwdrivers or other tools. Over-tightening the grip will cause the thread head attachment to decay. Make sure to not over-tighten the damaged screw.

Try using a screwdriver or an adjustable wrench to tinker with the screw. If that fails, then move on to other options.

How to Remove a Stripped Allen Screw?

You might think that using an electric drill on your stripped Allen screw is the solution, but it may not be the best idea. You can certainly put the screw in place using an electric drill, but there is no guarantee that you will be able to get that screw out again.

Instead of looking for short-term solutions like drilling a stripped Allen screw into a hole, look for other ways to remove it. There are many different methods to remove a stripped bolt or Allen screw. Here are a few that we like.

Penetrating Oil/Spray

The penetrating spray is an excellent solution for removing any stripped bolt or screw. A penetrating spray does what its name implies: it breaks the rust formed around the screw so you can reach in and remove it quickly.

Also Read: Removing rust from a bike

Materials

• WD-40
• PB Blaster
• Liquid Wrench
• Flathead screwdriver

WD-40 is a well-known brand of penetrating oil and water-displacing spray. This solution can be found in most households. It is a multi-purpose spray that comes in handy in dealing with many situations. A stripped Allen screw is just one of them.

PB Blaster and Liquid Wrench are penetrating oils used to loosen any rusted joints. They can loosen stripped Allen screws from the base. PB Blaster has a powerful odor, so please use it in a well-ventilated area.

Liquid Wrench and WD-40 do not have much odor; you do not have to worry about providing ventilation. You can use them in the basement or your garage if you want.

Follow the steps below to complete the job:

1. Use Penetrating Oil

First, use any penetrating oil or spray on the stripped Allen screw and wait for it to break up the stuck material. Wait approximately 15 minutes.

2. Dig Out the Screw with a Flathead Screwdriver

Once you see the oil has reached the screw and broken the surface, take a flathead screwdriver and dig out the broken pieces.

Hammer and Chisel

Using a hammer and chisel is one of the oldest tricks in the book when it comes to removing a stripped Allen screw. It is an easy solution that works just as well as any other method.

Materials

• Hammer
• Chisel
• Protective gear (gloves)
• Lubricant
• Pliers

Follow the steps below to complete this job:

1. Clean the Screw

At first, thoroughly clean the screw and its surroundings. Make sure to use a cold chisel before you proceed with the method.

2. Apply Lubrication

Apply some lubrication to the chisel’s tip. The lubricant should not be placed on the screw head.

3. Smash the Chisel

Put the chisel on the screw’s head and smash it hard. Do not hit it too hard with the hammer.

4. Hit the Screw with the Chisel

You should aim the cold chisel into the screw head. When you feel the screw move, start hitting it with the chisel again, but this time strike it so that the screw moves in a circular motion.

5. Repeat the Process

Continue repeating the above steps until you feel the hole’s hold on the screw loosening. Pliers can then be used to remove the screw from its place.

Welding

Welding is one of the fastest methods for removing stripped Allen screws. It may not be the most pleasant way of doing it, but it is effective.

Materials

• Safety gear
• Cleaning rags
• Wrench/pliers
• Welder
• Bolt head/nut
• Welding wire

Follow the steps below to complete the job:

1. Clean it Well

First, clean the area thoroughly. If the place is not clean enough, the nut will not stick to the screw properly. You can also use penetrating fluid before you start welding.

Also Read: How to clean your bike

2. Place the Bolt Head Right

Then, place your bolt head on top of the Allen screw head.

3. Set the Screw Head Right

After you start the welder, set the screw head on the inside of the bolt.

4. Pull the Bolt Head with Pliers

Now, use pliers or an adjustable wrench to pull the bolt head with the screw. If the screw does not move, keep repeating the process.

Drill Bits

Drill bits can remove stripped or damaged screws by using a drill. Consider using a left-handed drill bit since screw threads go clockwise.

With a left-handed drill bit, the flutes will go counterclockwise, which will help remove damaged Allen screws.

Materials

• Safety gear
• Cleaning rags
• Drill
• Drill bit
• A grinder
• A center punch

Follow the steps below to complete the job:

1. Clean and Make the Head Flat

Start by cleaning the area. Then, use a grinder to make the head flat.

2. Make Tiny Shallow Mark

Use a center punch to make a tiny, shallow mark on the head.

3. Put the Drill Bit Right

Then, put the drill bit in the drill. Your drill should have a reversible option for the rotary tool.

4. Place the Drill Tip Right

Place the drill tip on the mark and turn it on. As soon as the drill bit grips the screw, you can unscrew it.

Impact Wrench and Hammer

An impact wrench is a power tool designed to remove stubborn stripped screws from any surface. The wrench has a high rotational torque that helps with removing stripped Allen screws. The hammering mechanism in the wrench helps loosen any rusty bolts or screws.

Materials

• Safety gear
• Cleaning rags
• An impact wrench
• A small hammer
• Allen key socket

Follow the steps below to complete the job:

1. Clean It Well

Properly clean the area and the screwdriver. If the head or the driver is dirty, the Allen key will not fit properly.

2. Place and Hit the Allen Key Right

Put the Allen key in place and use a hammer to hit it. If you have any penetrating agent on hand, use some of it on the screw beforehand. It will help in loosening the screw.

3. Switch on the Impact Wrench

Then, place the impact wrench and switch it on. The screw should come right out.

Screw Extracting Kit

As you can guess from the name, a screw-extracting tool can remove any problematic screw or bolt. It is one of the easiest methods to remove stripped Allen screws.

Materials

• Safety gear
• Screw extracting kit
• Center punch (or something to make a new indentation)
• Drill
• Drill bit
• Hammer
• Threading oil

Follow the steps below to complete the job:

1. Make a Hole in the screw

Use a center punch and a hammer to put a hole in the screw. It will help guide you while using the drill. Put some threading oil on the screw. It will make it easier to drill.

2. Turn on the Drill

Use a drill slightly smaller than the screw. Put the drill in place and turn it on. Keep the drill steady while using it.

3. Insert Extractor

Once you have succeeded in making a hole (1/8 or ¼ inch deep), insert the extractor there.

4. Turn the Extractor

Turn the extractor clockwise. You might have to use a wrench to turn the extractor.

5. Turn the Extractor Counterclockwise

The extractor will go through the tiny hole you made and grip the screw tightly. Once you feel it gripping the screw, turn the extractor counterclockwise. The screw will soon come out.

Adjustable Wrench

Another easy way of removing stripped Allen screws is to use a rotary tool or an adjustable wrench. Please note that this method only works well when the Allen screw is lifted.

Materials

• Adjustable wrench
• Cleaning cloth

Now, follow these steps:

1. Clean and Fit

First, clean the screw with a cloth. Use an adjustable wrench to put it between the screw and the surface. Make sure it is a tight fit.

2. Turn the Wrench

Now, turn the wrench clockwise. Do not turn too slowly or too fast. Use a moderate jerking motion.

3. Tighten Your Grip

If the grip is firm enough, you will feel the screw loosening after a few turns.

Applying Heat

One of the most effective methods to remove Allen screws is applying heat. This method is not always advisable since you need something like a torch to provide the necessary heat. The stripped screws can easily get damaged if they are in wood or a similar surface.

Materials

• Safety gear
• Wet rag
• Fire extinguisher
• Torch lighter
• Allen wrench/pliers

Follow the steps below to complete the job:

1. Ensure Safety

Before you start, put on protective gear and make sure the fire extinguisher is within reach. Wipe the screw’s head with a wet cloth.

2. Use the Torch Right

Turn on the torch and place the flame directly towards the head of the screw. If you see any smoke, turn the torch off. Put a wet rag on the screw if it’s too hot.

3. Repeat the Process

Repeat the above a few times before removing the screw with an Allen key or pliers. Do not use your bare hands.

4. Cool It Down and Remove

Make sure you remove the screw when after it has cooled. Avoid removing it when there is still smoke coming out.

Frequently Asked Questions

Conclusion

Now that you know how to remove a stripped Allen screw, you can proceed with your next ride without much stress. To minimize the issues of stripped Allen screws, be cautious while putting them into any materials.

Screw heads are commonly broken due to carelessness. They can also get damaged by weather or moisture, causing the screw to rust.

You must be very cautious and use the right tools to fit your screw in properly. If you are conscious enough, the chances of stripping or damaging the Allen screws are minimal.

If you end up with a stripped Allen screw, you can easily remove it. All you need to do is pick at least one method from our list to get it out.