Step-by-step guide: how to drill out a broken screw in metal and save the day

Drilling out a screw in metal can be a daunting task, but with the right tools and techniques, it’s a manageable process. Whether you’re dealing with a stripped, broken, or rusted screw, this comprehensive guide will provide you with a step-by-step solution to remove it safely and effectively.

Materials You’ll Need

• Electric drill
• Drill bits (various sizes)
• Center punch
• Hammer
• Safety glasses
• Gloves
• Lubricant (e.g., penetrating oil, WD-40)
• Screw extractor (optional)

Safety Precautions

• Always wear safety glasses and gloves when drilling.
• Secure the metal workpiece to prevent it from moving.
• Use sharp drill bits to avoid damaging the metal.
• Keep the drill steady and apply light pressure.
• If the screw is severely rusted, apply penetrating oil and let it sit for several hours before attempting to drill.

Step-by-Step Guide to Drilling Out Screw in Metal

1. Center Punch the Screw Head

Use the center punch and hammer to create a small indentation in the center of the screw head. This will help guide the drill bit and prevent it from slipping.

2. Select the Correct Drill Bit

Start with a drill bit that is slightly smaller than the diameter of the screw. If the drill bit is too large, it can damage the surrounding metal.

3. Drill a Pilot Hole

Hold the drill perpendicular to the metal surface and start drilling a pilot hole in the center of the screw head. Drill to a depth of about 1/4 inch.

4. Increase Drill Bit Size

Change to a drill bit that is the same size as the diameter of the screw. Continue drilling into the pilot hole, applying light pressure.

5. Drill into the Screw

Once the drill bit has reached the bottom of the screw, continue drilling slightly into the metal. This will create a hole that is slightly larger than the screw.

6. Remove the Screw

If the screw is loose enough, you may be able to remove it using pliers. Otherwise, insert a screw extractor into the hole and turn it counterclockwise to remove the screw.

Advanced Techniques

7. Using a Left-Handed Drill Bit

If the screw is particularly stubborn, you can try using a left-handed drill bit. This type of bit turns counterclockwise, which helps to loosen the screw as you drill.

8. Applying Heat

Heating the screw with a torch or heat gun can help to loosen it, making it easier to drill out. However, be careful not to overheat the metal, as this can damage it.

9. Using a Dremel Tool

A Dremel tool can be used to grind away the screw head, making it easier to remove. However, this method should only be used as a last resort, as it can damage the metal surface.

Recommendations: Drilling Out Screws in Metal Made Easy

Drilling out a screw in metal can be a challenging task, but by following these steps and using the appropriate techniques, you can safely and effectively remove the screw without damaging the surrounding metal. Remember to always prioritize safety and use the right tools for the job.

Basics You Wanted To Know

Q: What is the best way to remove a stripped screw in metal?
A: Use a screw extractor to grip the stripped screw head and turn it counterclockwise to remove it.

Q: Can I use a regular drill bit to drill out a screw?
A: Yes, but it’s recommended to use a drill bit specifically designed for drilling into metal.

Q: How do I prevent the drill bit from slipping?
A: Center punch the screw head to create an indentation to guide the drill bit.

Q: What is the best lubricant to use when drilling out a screw in metal?
A: Penetrating oil or WD-40 are both effective lubricants for drilling into metal.

Q: Can I use a Dremel tool to remove a screw in metal?
A: Yes, but it should only be used as a last resort, as it can damage the metal surface.