Removing a small, stripped set screw can be frustrating, but there are several techniques you can try to loosen and extract it. One method involves using a liquid lubricant and an appropriately sized hex key, as demonstrated in a helpful video guide.
Method Using Lubricant and Hex Key
Based on the technique shown in the video "How to Remove a Stripped Allen Screw - YouTube", you can attempt the following:
- Add Liquid: Add a couple of drops of a suitable liquid (often penetrating oil or lubricant works well) to the stripped set screw head. This can help to penetrate threads and break down any rust or corrosion.
- Insert Tool: Push your hex key (or Allen key) firmly into the screw head. Ensure it's the correct size for the screw, even though it's stripped. Apply downward pressure to help the key engage with any remaining edges inside the hex socket.
- Turn Slowly: Begin turning the hex key counterclockwise. Apply steady, firm pressure while turning. The lubricant combined with firm pressure might allow the hex key to grip enough to rotate the screw out.
- Practical Tip: For tiny set screws, using a high-quality, sharp hex key is crucial. Sometimes, slightly tapping the end of the hex key while applying turning pressure can help it bite.
Other Techniques for Stripped Set Screws
If the lubricant and hex key method doesn't work, consider these alternative approaches:
- Use a Rubber Band: Place a wide rubber band over the stripped screw head. Insert your hex key through the rubber band and into the screw. The rubber band can sometimes fill the void created by the stripping and provide extra grip for the tool.
- Try a Torx Bit: Sometimes, a slightly larger Torx (star-shaped) bit can be gently tapped into the stripped hex socket of a set screw. Torx bits have more points of contact than hex keys and can sometimes grab the damaged edges. Choose a size that is just slightly too large and carefully tap it in before trying to turn.
- Screw Extractor: For severely stripped screws, a small screw extractor kit might be necessary. These kits include drill bits designed to drill a pilot hole and extractors that screw into the hole and grip the screw from the inside, allowing you to back it out. This is often a last resort as it requires drilling into the screw.
- Heat or Cold: Applying localized heat (carefully, with a soldering iron tip if the material allows) can sometimes cause the screw or surrounding material to expand, potentially loosening the screw. Conversely, applying cold (like using electronic freeze spray, again, with caution) can cause contraction.
- Sharp Tool and Hammer: For stubborn screws where appearance isn't critical, a small, sharp punch or chisel can be used with a hammer to try and tap the screw counterclockwise at its outer edge.
| Technique | Description | Use When... |
|---|---|---|
| Lubricant + Hex Key | Add liquid, insert key with pressure, turn counterclockwise. | Socket is slightly rounded, threads might be seized. |
| Rubber Band | Place rubber band over screw, insert tool through, turn. | Socket is moderately rounded. |
| Torx Bit | Gently tap Torx bit into socket, turn counterclockwise. | Socket is significantly rounded, needs new grip. |
| Screw Extractor | Drill small hole, insert extractor, turn screw out. | Socket is completely destroyed, other methods fail. |
| Heat / Cold | Apply localized heat or cold to the screw or surrounding material. | Screw is seized by rust or thread locker. |
| Sharp Tool / Hammer | Tap edge of screw head counterclockwise with punch/chisel. | Screw head is accessible, appearance is not critical. |
Remember to wear appropriate safety glasses when using tools, especially when tapping or drilling. Always start with the least destructive methods first.
