[Poot]

I managed to strip the head on a very small hex screw, and now the correct size wrench won't work. What's the best way to attack this problem, and finally extract the screw?

Thanks for sharing your experience,
Pat

 

[HerrMesser]

Is there any way to get vice grips on it? Or you might drill a hole and use a ez out in a tap handle. Or drill the head off and disassemble then remove the screw.

Rad

 

[Clyde]

Can drive the next-smaller size (MIGHT have to go two sizes down) box end or socket wrench onto the head and turn it out. IF the head stands sufficiently proud of the surface.

Can also use a cut-off wheel to cut a slot and turn it into a conventional slotted screw.

Could be it is too small and soft for either of those solutions to work, of course.

 

[curly1]

Is the hex slot totally rounded out?

Will the correct size at least start to bite?

If it does try soaking in Kroil oil then a little heat if you think you can heat it w/o damaging the surrounding area.
Then try the hex wrench correct or smaller size.

Try squaring up the stripped portons of the screw with a very small drill bit if there is enough area to work with.

 

[greyheadedguy]

can you use some of that Permatex Stripped thread repair stuff. (http://www.roguemotorsportz.com/i6881/Permatex_Stripped_Thread_Repair.aspx?sc=Google&ad=Products) Put the release agent on the allen wrench and the the thread epoxy in the head of the bolt? Or just epoxy a cheap allen wrench into the bad bolt and remove and discard.

 

[mg34nz]

Slotting it to make a screw or filing is a good suggestion also if its accessible enough and not to small you could TIG weld another bolt/screw to the damaged one and then wind it out,I have done it before many times provided its feasible for the situation at hand and you have the equipment available or a friend who can do it.As i said it works well but only where you can do it without risk of further damage.

 

[Poot]

Wow, thank ya'll for the great (and swiftly delivered) feedback. I'll try using a cutting wheel and cutting a slot for a standard screwdriver. That's a beautifully simple idea, I like it! Barring that, I'll try the epoxy trick if that doesn't work.

Thanks again,
Pat

 

[Shoobedoo]

Can also use a cut-off wheel to cut a slot and turn it into a conventional slotted screw.

A hacksaw will sometimes work for this purpose as well, just go slow and be careful no to go too deep. If the screw is not torqued in there too tightly it should back right out. This is one reason I'm not a big fan of allen head screws, especially some of the smaller ones, they strip very easily.

 

[jjk308 In Memoriam RIP]

First mix some penetrating oil with about 1/3 acetone and drip some on it, cover with aluminum foil to delay evaporation and let it soak in. Much better at breaking stuff loose than any penetrating oil alone. But keep it off of plastic and oil finishes.

 

[wrench]

I've used a Torx bit to get out stripped allen head screws several times. You need to find the right size to fit into the stripped hex with a little help from a hammer. Then just turn it out.
Cutting a slot is easier if you have access, of course.

 

[chuckindenver]

these should be in everyones tool box
http://www.rockler.com/product.cfm?page=25079&site=ROCKLER&uuid=&sli_sid=

the pro grabit...they are pretty sweet

 

[greyheadedguy]

these should be in everyones tool box
http://www.rockler.com/product.cfm?page=25079&site=ROCKLER&uuid=&sli_sid=

the pro grabit...they are pretty sweet

I have set of those and forgot all about them... Too many other toys I guess...