4 Ways to Remove a Stripped Set Screw

Dealing with a stripped set screw can be a frustrating experience, especially when it seems impossible to get any grip on the damaged screw head. But don't worry, there are several tried-and-true methods to help you remove that stubborn screw without damaging your project further. Below are the top five ways to remove a stripped set screw, even when it seems like no tool will work.

1. Rubber Band or Steel Wool Trick

If the set screw is only mildly stripped, you might get lucky with a simple solution: using a rubber band or a piece of steel wool. Place the rubber band or steel wool over the stripped screw head and push your hex key or screwdriver firmly into the damaged area. The added friction can help your tool catch enough to turn the screw. This trick works surprisingly well when the damage is not too severe, and it's often the easiest option to try before going for more drastic methods.

2. Use a Screw Extractor

A screw extractor kit is your best bet for more severely stripped set screws. These kits are specifically designed to deal with damaged screws. The extractor bit is drilled into the damaged screw head on one side, and then the bit is flipped within the drill and used such that its reverse-threading removes the screw. Search for screw extractor kits, or for a high quality set, try Grabit's Micro Screw Extractor. For tiny screws, you'll need to use the #0 screw extractor which works on screws as small as 2-3mm diameter as shown below.

3. Drill Out the Screw

For screws that are completely stripped and can’t be salvaged, drilling out the screw may be the only option. To do this, use a drill bit slightly smaller than the screw shaft, and carefully drill into the center of the set screw. For the 8-32 set screws used in our products, we recommend a 1/16" drill bit like this one from Bosch. This can either loosen the screw enough to remove it or destroy it completely, allowing you to clear out the hole and replace the screw. Be cautious with this approach to avoid damaging the surrounding material.

4. Cut a New Slot

If the screw head is still somewhat accessible, you can use a Dremel tool or a small hacksaw to cut a new slot into the top of the screw. Once the slot is made, use a flathead screwdriver to remove the screw. This method can work wonders for a screw that’s stripped but still has some material to work with. The key here is to cut the slot deep enough to allow for firm engagement with the screwdriver.

Bonus Tips:

• Lubricate and Heat: Applying penetrating oil (like WD-40) to the screw before attempting removal can help loosen any rust or corrosion. If that doesn't work, applying heat using a soldering iron can expand the metal and make the screw easier to remove.
• Left-Handed Drill Bit: If you're drilling out the screw, using a left-handed drill bit can sometimes reverse the screw out as you drill.

Stripped set screws can be a challenge to tackle, but for best results, take time to obtain the proper tools and take care to avoid causing damage to the surrounding materials. Happy troubleshooting!