How to Remove a Stripped Allen Wrench Screw?

The Allen screw is a fastener with hexagonal groove holes on the screw head. The Allen key screw head is small in size and is very suitable for installation in narrow spaces. Due to their small size, they are prone to stripping. Once stripped, these Allen key screws become hard to handle. Here are some tips to teach you how to remove a Allen wrench screw.

How to Take Out Stripped Allen Screws?

When taking out stripped Allen screws, different tools and materials should be used depending on the wear and tear of Screws，here are some tools and materials you'll need：

Allen wrench set

Needle-nose pliers 

Torx wrench 

Hot air gun 

Screw extractor kit 

Drill 

Left-hand drill bit 

Angle grinder

Rotary tool  

Hacksaw 

Screwdriver set

Epoxy resin glue 

Masking tape 

How to Get a Stripped Allen Key Screw Out​?

1.Quick Fixes: Easy, Low-Cost Methods

Change Another High-quality Allen Wrench

Generally，the fastest way for removing stripped Allen screw ​is to change a different Allen wrench. After long-term use, the hexagonal edge of Allen wrench may be worn round, resulting in a gap between the tool and the screw hole, which cannot transmit sufficient torque.

Use a Larger Hex Key  

Sometimes Allen wrench screw stripped because the original hexagonal hole has been enlarged, and now a larger Allen wrench can be tapped in:

• Choose an Allen wrench that is approximately 0.5mm larger than the original specification to avoid damaging the allen screw if the size is too large. 

• Point Allen wrench at the center of screws.

• Tap the hex key gently.

• Maintain a stable pressure, apply torque counterclockwise to avoid slipping again.

Use Needle Nose Pliers

If any part of the allen screw is exposed, you can try to clamp it with a pointed-nose pliers and rotate it. This method is suitable for situations where there is sufficient clamping space, and it should be noted that the jaws can easily damage the surface of the components.

2.Intermediate Methods: Alternative Bits and Heating

Consider the Torx Wrench 

Another wrench you might consider is a Torx wrench. Torx wrenches are designed for Torx screws, which have something of a star pattern with six points.The Torx wrench key fits well into the stripped allen screw. But in this case, the tip of your torx wrench may get damaged.

Heating the Screw Reduces the Locking Force

If the surrounding environment is not flammable, you can consider using a hot air gun to heat the screw. Many screws come loose due to the thread adhesive being fixed, rusting, corroding or long-term heating and cooling causing the thread to get stuck. This can be solved by locally heating the screw to make the metal expand due to heat. At this point, disassemble the screw.

3.Advanced Methods: Drilling and Screw Extractors

Use a Screw Extractor Kit

Removing a stripped screw with a screw extractor is a reliable repair method. The extractor features left‑hand threads. First, drill a small hole in the center of the stripped Allen screw. Then insert the extractor so it grips the inside. Turning it counterclockwise makes it dig in and apply reverse torque, pulling the damaged screw out.

Use a Left-Hand Drill Bit

A left-hand drill bit spins in the reverse direction compared with a standard bit. As it bores into a threaded screw, it turns counterclockwise, creating a loosening torque. During drilling, this reverse rotation may back the screw out completely without extra tools. In this way, it performs both drilling and screw removal at the same time.

4.Last-Resort Methods: Cutting and Epoxy Tricks

Cut a Slot

If all of the above methods fail,  the stripped Allen screw must be removed quickly. At this point, the hexagonal holes of the Allen screw have been severely worn. Cutting a new slot is the most effective method. The following several methods can help you cut out a slot:

• Use an Angle grinder to cut a small slot on the top of the allen screw. 

• Use a rotating tool and a grinding wheel to cut a small slot on the screw. 

• Use a hacksaw to cut a thin slot on the screw. 

After the cutting is completed, use a flat-head screwdriver to apply rotational torque through the new slot and remove the sliding screw. 

Use Epoxy and a Screwdriver

Epoxy adhesive has strong bonding power and can help restore the bond between the tool and the screw. First, clean the oil stains and impurities inside the hex socket holes. Then, fill the holes with epoxy resin glue and insert a flat-head screwdriver or hex socket tip wrapped in masking tape.

After the glue has fully cured, keep the tool upright and slowly turn it counterclockwise. Use the adhesive bond to remove the sliding screw. Be careful to avoid the glue overflowing around the screws. Do not apply excessive torque, otherwise it will cause the bonding to fail.

FAQ

1.Can a rubber band really remove a stripped screw?

Rubber band can help remove slightly stripped screws, but it is not applicable in all situations. It uses rubber material to increase the friction between the allen wrench and screw. The rubber band is placed between the wrench and the screw to enhance the grip and unscrew the screw. But if the allen wrench screw is severely worn out, this method won't work.

2.Is it better to drill or extract a stripped screw? 

This depends on the degree of damage to the screw and the specific usage scenario. 

For the case of mild thread slippage, screw extractor is more suitable. It can remove the screw without damaging the fastener. 

Drilling is suitable for situations where an allen screw is severely damaged or broken, but attention should be paid to the size and depth of the drilling.

3.What are common mistakes when removing stripped screws?

Using an allen wrench of the wrong size is the most common cause of slippage. If the size and shape do not match, it is more likely to slip during operation. Therefore, before disassembling, please ensure that the tool is a perfect match.

Final Thought

As long as you handle the correct method, it is not difficult to remove the stripped hex socket screw. Diversitech Global is an experienced hardware tool set supplier in China. Our team has rich OEM/ODM experience and can provide you with the most market-competitive wrench set, home tool set, professional tool set, etc. Contact us!