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Tips

Screw removal?

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aerog

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I've got several structural-grade screws (about 1/4" heads) that are frozen solid, and despite their strength the heads have managed to become stripped.

Any recommendations on screw remover tools that are relatively fool proof?
 
The best screw removal tool I have found are left hand drill bits. If you start with a fairly small centered hole, & progressively increase size, the screw is almost certain to back itself out before the drill is all of the way through. Any good tool store should have the "backward" bits.
D
 
That's probably one of the better ways from what I gather. It sounds like the theory behind some of the Craftsman tools. I'm trying to avoid drilling the screw first (ie: EZ-Out).
 
EZ-Outs are not a very good tool. By design, they wedge into the center hole to grip. This tends to expand the screw body & make the screw even tighter in the hole. Combined with the tool being weak & brittle, a receipe for trouble. IMOP, truly mis-named "EZ". OTOH, the drill grabs at the bottom of the hole & doesn't expand the screw.
D
 
Soak the screw with PB Blaster for as long as possible this stuff is the best I've found for getting frozen stuff un-stuck if you have to drill the left hand drill bits work good as long as you don't just drill the head off try to leave some threads so you can grab the threads with good old visegrips good luck
 
I agree with the drill method, although I've used EZ-Outs also. Drilling has worked every time. I've even used standard right-handed drills to make a hole and then tapped a small phillips head or similar into the hole and turned it out. I have never destroyed the internal threads to the point where I had to drill & tap a larger hole or had to Helicoil it.
 
This might not help you with the screws you are trying to remove now, but this impact driver fitted with the appropriate bit will remove just about any screw, bolt or nut. They are especially useful for slotted and phillips type screw heads.

You just have to remember it's in the tool box BEFORE the heads of the screws get too messed up. /ubbthreads/images/graemlins/eek.gif
 
Hi Scott
I have watched the master machinist at work remove severely damaged bolts many times. He just drills them out. For this to be successful it is important to be fairly well centered. Also, these are structural, can you get them to a drill press? otherwise use one of those portable drill guides. Start with a small bit, and get is very well centered. Then continue drilling out using progressively larger bits.
If you have reverse threaded bits then fine, my "guru" uses regular bits. When you get close to the end, use a tap to knock the remnant out.
Also, if these are blind bolts, remember to be careful not to drill to deep!
Let us know how it goes.
Yisrael
 
[ QUOTE ]
Also, these are structural, can you get them to a drill press? otherwise use one of those portable drill guides.
Yisrael

[/ QUOTE ]

Thanks for the tips everyone, I've been avoiding "EZ-Outs" for the obvious reasons you've all stated /ubbthreads/images/graemlins/smile.gif

Yisrael: Unfortunately no, the screws are in the top of an airplane wing (high wing at that). There are 42 screws that hold a sheet-metal cover onto the wing that covers a fuel tank (the tank is essentially a metal jerry-can laying on its side, held in position with two straps).

I've aquired a kit of "removal tools". Each has a small bit to drill into the top of the screw, then on the flip-side a reverse bit to dig into the screw and back it out. The guy I borrowed them from swears by them so, we'll see!

-sk
 
[ QUOTE ]
This might not help you with the screws you are trying to remove now, but this impact driver fitted with the appropriate bit will remove just about any screw, bolt or nut. They are especially useful for slotted and phillips type screw heads.

You just have to remember it's in the tool box BEFORE the heads of the screws get too messed up. /ubbthreads/images/graemlins/eek.gif

[/ QUOTE ]

That's the problem! These screws were already not in the best of shape, and the heads aren't exactly holding up well to much torque.

There's a rivet-gun attachment that sounds similar to the cooltools thing; from what I gather you twist it with a wrench while letting the tool do it's thing.
 
If the heads are gone and the broken screw body is flush with the sheet metal cover for the gas can why can't you drill a hole next to it and put a new screw in there and leave the broken screw where it is? Possible aerodynamic problems? If the entire cover for the gas can is removed you may gain enough of the top of the screw body to grab a hold of them but then again you probably risk stripping off more of the screw heads. I cannot think of anything other than drilling them out carefully and slowly.

Otherwise I would think you probably need to talk to a good Cessna mechanic.
 
That wouldn't have worked Harry, at least not without modifying the aluminum blocks under the skins (plus the paperwork involved in doing it).

In any case - I had a chance to try these tools I borrowed. I really took my turn with the first one, drilled into it enough so the "reverse bit" could grab. First couple of tries didn't work (I didn't drill in enough), finally the bit grabbed and after awhile I got it to break free. The other 5 I had were easier and they came out quickly. Nice tools, similar to what Sears/Craftsman offers.
 
This sounds like a barbaric method but I watched a guy years ago take the bolts out of my motorcycle motor which I had stripped out the philips head with a screwdriver. The heads were rounded and he took a punch and tapped a notch into the side of each screw and continued tapping in the direction that the screw would come out and they came right out. I have used that method many times since then when all else fails and it usually works. Of course, if you have no head left, it wont work.
Bob
 
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