Rusted screws are more than just an eyesore; they’re a common frustration for DIY enthusiasts and professionals alike. A rusted screw can resist your best efforts to unscrew it, and if you apply too much force, you risk damaging the screw head or even breaking it off completely. This can lead to even more complex problems and potentially ruin the material you are working with. Before you resort to forceful methods that could cause further damage, understanding the right techniques for removing a rusted screw is crucial. This guide will walk you through proven methods on How To Get A Rusted Screw Out without causing unnecessary damage.
Methods to Remove Rusted Screws
When facing a stubborn, rusted screw, patience and the right approach are your best allies. Instead of immediately reaching for brute force, consider these effective methods, ranging from simple to more advanced techniques.
1. Lubricant and Percussive Maintenance: The Gentle Approach
Often, rust acts like glue, binding the screw tightly in place. The first step in how to get a rusted screw out should always be to try and break this bond gently. This is where lubricant and “percussive maintenance” come in handy. Before reaching for power tools or excessive force, try this method:
- Tapping: Use a hammer to gently tap the head of the rusted screw a few times. This helps to loosen the rust particles and create tiny pathways for lubricant to penetrate.
- Apply Lubricant: Apply a generous amount of penetrating oil or all-purpose lubricant to the area around the screw head. Ensure the lubricant seeps into the screw threads as much as possible.
- Wait and Repeat: Allow the lubricant to work for at least 15-30 minutes, or even longer for heavily rusted screws. Reapply lubricant and tap the screw head again periodically to encourage penetration.
- Attempt to Unscrew: After the lubricant has had time to work, try using a screwdriver or a drill with a screwdriver bit to turn the screw counterclockwise. Apply steady, even pressure, and avoid stripping the screw head.
This initial approach is often sufficient for screws that are not excessively rusted. Patience is key here; allow the lubricant to do its job and avoid rushing the process.
2. Leverage with Pliers: When the Screw Head Protrudes
If the head of the rusted screw is protruding from the surface, you can gain better leverage using pliers. This method is particularly effective when combined with rust penetrant.
- Apply Penetrant: Begin by applying penetrating oil to the rusted screw and let it soak in, as described in the previous method.
- Grip with Pliers: Use channel-lock pliers or vise-grip pliers to firmly grip the head of the protruding screw. Vise-grips are particularly advantageous as they can lock onto the screw head, providing a secure hold.
- Turn Counterclockwise: Slowly and steadily turn the pliers counterclockwise to unscrew the rusted screw. Apply consistent pressure and avoid jerky movements that could break the screw head.
- Lubricate and Tap if Needed: If the screw remains stuck, reapply lubricant and gently tap the screw head while maintaining grip with the pliers. This can further help break the rust bond.
Using pliers provides increased torque and a better grip, which can be crucial for how to get a rusted screw out when manual screwdrivers are insufficient.
3. Screw Extractor Kit: For Damaged or Broken Screws
When a rusted screw is severely damaged, stripped, or even broken, a screw extractor kit becomes your best bet. These kits are specifically designed to remove screws with compromised heads.
- Prepare the Screw Head: Use the drill bit included in the extractor kit to carefully smooth out the damaged head of the screw. This creates a clean surface for the extractor bit to grip.
- Engage the Extractor Bit: Select the appropriate size spiral extractor bit from the kit. Place the extractor bit onto the prepared screw head.
- Reverse Drill: Using a drill in reverse (counterclockwise) direction, apply steady pressure to engage the extractor bit into the screw head. The spiral design of the bit is meant to “bite” into the metal as it turns in reverse.
- Extract the Screw: Continue applying reverse pressure and turning slowly. The extractor bit will gradually dig into the screw head and, as it gains purchase, begin to unscrew the rusted screw.
Always wear gloves when using an extractor kit, as metal shavings and sharp edges can be produced during the process. This method is a more advanced solution for how to get a rusted screw out when other methods fail due to screw head damage.
4. Applying Heat: Expanding Metal to Break Rust
Heat can be a useful ally when dealing with rusted screws, particularly those in metal or those with seized washers. Heat causes metal to expand, which can help break the rust’s grip on the screw threads.
- Apply Heat Source: Use a heat gun or even a hairdryer to apply heat to the area around the rusted screw. For metal components, you can use a heat gun more directly. Exercise caution when applying heat near flammable materials.
- Heat Cycle: Heat the area for a minute or two, then immediately try to turn the screw. The expansion and contraction of the metal as it heats and cools can help loosen the rust.
- Combine with Percussive Maintenance: After heating, give the screw head a few firm taps with a hammer to further assist in breaking the rust bond.
- Attempt to Unscrew: After heating and tapping, immediately try to unscrew the rusted screw using a screwdriver or pliers.
While a hairdryer might suffice for lightly rusted screws, a heat gun provides more concentrated heat for tougher cases. This method is particularly effective for how to get a rusted screw out of metal components.
5. Creating a New Slot: For Stripped Screw Heads
If the head of the rusted screw is stripped, meaning the screwdriver bit no longer has purchase, you can create a new slot for a flathead screwdriver.
- Cut a Slot: Using a hacksaw or a rotary tool with a cutting disc, carefully cut a slot across the head of the screw. Make the slot deep and wide enough to accommodate a flathead screwdriver.
- Use a Flathead Screwdriver: Insert a flathead screwdriver into the newly created slot.
- Apply Turning Force: Turn the flathead screwdriver counterclockwise to unscrew the rusted screw. For added leverage, you can use a wrench on the handle of the screwdriver or use a drill with a flathead bit.
Creating a new slot provides a fresh point of contact for a screwdriver, offering a solution for how to get a rusted screw out when the original screw head is compromised.
Conclusion: Patience and Persistence are Key
Removing a rusted screw can be challenging, but with patience and the right techniques, it’s definitely achievable. Remember to start with the least invasive methods, like lubricant and gentle tapping, and gradually progress to more assertive techniques like using pliers, extractor kits, heat, or creating a new slot if necessary. By understanding these methods, you’ll be well-equipped to tackle rusted screws and avoid causing further damage to your projects. The key takeaway when considering how to get a rusted screw out is to proceed with caution, patience, and the appropriate tools for the job.
