How to Remove a Stripped Allen Screw

Follow this sequence for how to remove an Allen screw in order since the methods increase in intensity. If a method isn't working, don't force it. Instead, move to the next method. Allen screws always open counter-clockwise.

1. Lay a Rubber Band or Paper on Top

   Lay a wide rubber band or sheet of paper over the Allen screw. Insert the correctly sized Allen wrench over the paper or rubber band and turn.

2. Switch to T-Handle Hex Wrench

   The usual L-shaped Allen wrenches are thin and difficult to handle. Use a set of T-handle Allen hex wrenches for better hand grip and improved downward pressure.

3. Add Screw-Grab Friction Liquid

   Screw-grab friction liquid creates a positive grip on screws to increase torque with less slipping. Add one drop of screw-grab friction liquid to the top of the Allen screw. Insert the correctly sized Allen wrench and turn.

4. Turn With a Larger Allen Wrench

   Stripping an Allen screw widens its internal hex shape. Move up to the next-sized Allen wrench and turn with that.
   

   Tip

   There are both SAE and metric sized allen wrenches. It is good to have both available for proper fit.

5. Turn With a Torx Wrench

   Torx is a trademarked screw and wrench with a six-point star-shaped pattern. A similarly sized Torx wrench might provide a firmer grip on a stripped Allen screw. Or you might even discover that you actually have a Torx screw, not an Allen screw.

6. Turn With a Phillips Head Screwdriver

   Insert the tip of a Phillips head screwdriver and turn the Allen screw.

   Tip

   Take your time and go easy to avoid stripping out the Allen screw even more.

7. Apply Heat

   If the surrounding material is not flammable, apply heat from a small propane torch for just a few seconds, then turn the screw.

8. Grab With Needle-Nose Pliers

   If any part of the Allen screw head is exposed, grab it with needle-nose pliers and turn. If the Allen screw is embedded in wood and you don't mind gouging the wood, press into the wood so you can grip more of the screw head.

9. Use a Left-Hand Drill Bit

   Left-hand drill bits are the same length and diameter as conventional drill bits except that the spiral turns leftward.

   From the set, choose a left-hand drill bit that's narrower than the assumed diameter of the Allen screw (the shank will usually be smaller than the head). Insert a left-hand drill bit into an electric drill. Keeping the drill vertical, drill into the Allen screw until it turns out.

   Tip

   Remember to switch the drill rotation to REVERSE.

10. Create a Groove to Turn With a Screwdriver

    Place a metal cutting wheel into a rotary cutting tool. Cut a shallow groove into the Allen screw head. Switch to a flat-head screwdriver and turn out the Allen screw.

11. Use a Screw Extractor Kit

    A screw extractor kit is much like a set of left-hand drill bits except heavier and larger in diameter. Screw extractor bits start at 3/16-inch. Add the screw extractor bit to the drill or the manual T-shaped handle. Turn the bit counter-clockwise into the Allen screw until the screw emerges.

12. Use a Two-Part Epoxy

    Choose an Allen wrench or T-shaped hex wrench that fits the Allen screw as tightly as possible. Mix two-part epoxy composed of a resin and a hardener. Often, this is done by squeezing a double-barreled applicator to form a single compound. Other two-part epoxies are mixed from separate containers on a piece of cardboard or another disposable material.

    Glue the wrench firmly to the Allen screw. You may need to wait up to 12 hours for the epoxy to fully cure. Then, turn the screw out.