Removing damaged screws - any tips / tricks?

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openmedia

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#302925 4-Jan-2023 14:22

Trying to replace some window handles and the type 1 square drive screws are damaged and won't move

https://www.yalehome.com/nz/en/products/window-products/window-handles/wedgeless-handles/wedgeless-aria

I've tried using a screw removal tool and attempted to drill the screw out, but even using a power drill I'm struggling to make much of an impact.

https://tradedepot.co.nz/tdx-screw-extractor-pack-of-4

I can't cut a notch due to the way the screw is mounted, and I've looked at similar guides to these for tips

https://www.instructables.com/5-Ways-to-Remove-a-Stripped-Screw/

I feel I'm not using the screw extractor correctly so any tips would be appreciated.

Generally known online as OpenMedia, now working for Red Hat APAC as a Technology Evangelist and Portfolio Architect. Still playing with MythTV and digital media on the side.

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#3016867 4-Jan-2023 14:44

"I've tried using a screw removal tool and attempted to drill the screw out, but even using a power drill I'm struggling to make much of an impact."

You want lots of low speed Torque to get a screw out... A Fully charged battery drill might be a better bet than a corded one??...

Also make sure the extractor bits are used in reverse when you are both drilling it and then extracting it with the "round" end..

Also its likely there's some corrasion on the screw treads, lots of CRC is also likely to be helpful...

Rikkitic

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#3016868 4-Jan-2023 14:44

Square drive screws are supposed to avoid this kind of problem. How are they damaged?

I have had good luck with screw extractors. Use a metal bit of suitable size to drill a round hole into the screw, which the extractor can then burrow into. Works like magic for me.

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Technofreak

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#3016874 4-Jan-2023 14:53

Rikkitic:

Square drive screws are supposed to avoid this kind of problem. How are they damaged?

I have had good luck with screw extractors. Use a metal bit of suitable size to drill a round hole into the screw, which the extractor can then burrow into. Works like magic for me.

Screw extractors need a hole to bite into.

Do as Rikkitic says and drill down into the screw with a drill bit that is very slightly smaller in diameter to the extractor, then apply the extractor to that hole.

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tweake

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#3016875 4-Jan-2023 14:55

a lot of screw/bolt removal articles are complete BS, because the bolts they use are not stuck. typically the reason the screw is munted is because its rusted in there.

easyouts etc only work well if its NOT seized in the hole. using heating/cooling and penetration lube to free it first will help. penetration lubes need time to soak in and work down the thread. putting more on does not make it go faster.

gbwelly

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#3016883 4-Jan-2023 15:20

Would love a pic. If the square drive is now a round hole, without seeing pics, I'd find the next size up bit and hammer it in so it's just sitting wedged in. Then click on the cordless impact driver and hit it hard in one shot. Hammering in a torx bit into a flogged out hex hole works really well. If the screw head is basically round now then a torx bit hammered in might do the job. Obviously as it's in a window take whatever means necessary to not smash the glass when you strike it.

insane

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#3016885 4-Jan-2023 15:21

Might need to pickup some carbide tipped drill bits if your usual HSS ones aren't making a dent in the hardened screws.

Irwin have a well priced set.

neb

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#3016893 4-Jan-2023 15:57

wellygary:
Also make sure the extractor bits are used in reverse when you are both drilling it and then extracting it with the "round" end..

That's an important point, extractor bits aren't just "whack it in and hammer away", first you need to bore out the damaged head with one end of the extractor, then flip it around and use the extractor bit in the bored-out area, both in reverse mode.

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pih

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#3016895 4-Jan-2023 16:04

Another idea: you said that cutting a notch (I'm assuming by hacksaw) won't work "due to the way the screw is mounted", but does that also apply for a Dremel-style rotary tool and cutting disk? I've successfully done this several times and if you don't have a Dremel it's a good excuse to go and buy one 😉

Also would like to see a pic of you can upload one.

JimmyH

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#3017227 5-Jan-2023 10:47

I had to get out six heavily rusted-in window screws a few years ago. Nothing in the usual repertoire would shift them, including my 18V impact driver and a screw remover set. In the end I used an ancient impact driver set my dad had back in the day (40+ years old). It wasn't electric, it was the type where you slot the right bit in, place it in what's left of the screw head, and use bloody great whacks with a hammer to both jolt the screw and make it turn.

It wasn't identical to, but from memory was similar to, this: https://www.mitre10.co.nz/shop/fuller-impact-driver-1/2-inch-silver/p/255548

It took over an hour, accompanied by much whacking and much swearing, but eventually it moved them all.

Bung

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#3017234 5-Jan-2023 11:10

Bloody great whacks would probably destroy most modern window frames.

insane

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#3017241 5-Jan-2023 11:23

The manual impacts are pretty good though as it applies downwards pressure and torque at the same time.

Could work if you can get the sash out easily and support it from behind.

I'm interested to know how this turns out :)

lchiu7

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#3017453 5-Jan-2023 16:18

I had a similar problem with the handle on an aluminium window. The screw had got munged and I tried a bunch of different tools to get it out with no luck. In the end I gave up and called in a window repair company and he drilled out the screw. I guess I could have done that but I didn't have the right bits.

neb

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#3017456 5-Jan-2023 16:25

lchiu7:
In the end I gave up and called in a window repair company and he drilled out the screw. I guess I could have done that but I didn't have the right bits.

That's something that's going to be tricky to DIY since you're drilling out a hard steel screw from soft thin aluminium, unless you do it just right the bit is going to take the easy route in which is through or into the alu.

For anyone else trying this, I would spend about a week applying penetrating oil (so once or twice a day) and also try heat, alu wicks away heat like crazy but if you can heat the screw itself it may break free.

openmedia

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#3018592 8-Jan-2023 15:05

Here are what the screws currently look like

I've just tried to use a set of these removal and the screw is stripping the threads off the removal tools.

https://www.mitre10.co.nz/shop/fuller-screw-extractor-set-5-piece/p/255538

Generally known online as OpenMedia, now working for Red Hat APAC as a Technology Evangelist and Portfolio Architect. Still playing with MythTV and digital media on the side.

Bung

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#3018596 8-Jan-2023 15:14

If you drilled the heads off and then couldn't remove the rest of the screw just move the latch sideways enough for new screw holes.

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