How to Remove Worn-Out Screws

Before attempting to remove a worn-out screw, it's essential to understand what caused it to become difficult to remove. Worn-out screws can result from several factors. Over-tightening can strip the threads, making it impossible to turn the screw with a normal screwdriver. Corrosion can also bind the screw in place, especially in outdoor or humid environments. Additionally, screws that have been in place for a long time may have seized due to rust or debris buildup around them.

Tools You'll Need
Screwdrivers: Different sizes and types, such as flat-head and Phillips-head, are essential. Sometimes, a precision screwdriver set can be useful for small screws.
Pliers: Needle-nose pliers or locking pliers can be handy for gripping the screw head.
Impact Driver: This tool uses a series of short, sharp blows to help break the screw free.
Drill: A drill with the appropriate bit size can be used to drill out the screw if other methods fail.
Screw Extractor Set: Specifically designed tools for removing broken or stripped screws.

Methods for Removing Worn-Out Screws

1.     Use the Right Screwdriver
If the screw head is only slightly worn, try using a screwdriver that fits the head perfectly. A loose-fitting screwdriver can further damage the screw head.   For a flat-head screw, ensure the blade of the screwdriver is the correct width and thickness.   For Phillips - head screws, use a screwdriver with a tip that matches the size and depth of the recess.   Apply firm pressure while turning counter-clockwise to remove the screw.

2.     Apply Penetrating Oil
If the screw is stuck due to corrosion or rust, applying a penetrating oil can work wonders. Spray the oil generously onto the screw and let it sit for 15 - 30 minutes. This gives the oil time to penetrate and break down the rust or corrosion.   Afterward, try turning the screw with a screwdriver.

3.    Use Pliers
When the screw head is too worn for a screwdriver to grip properly, pliers can be a great alternative.   For small screws, needle-nose pliers can be used to grip the head. For larger screws, locking pliers can provide a stronger grip.   Grip the screw head firmly and turn it counterclockwise.   Be careful not to apply too much force, as this can cause the screw to break.

4.   Employ an Impact Driver
An impact driver is a powerful tool for removing stubborn screws.  Insert the appropriate bit into the impact driver and place it on the screw head.  Apply firm pressure and strike the back of the impact driver with a hammer.  The series of impacts can help break the screw free from the material.  This method is beneficial for screws that are tightly stuck due to vibration or long-term use.

5.   Drill Out the Screw
If all else fails, drilling out the screw may be necessary.  First, select a drill bit that is slightly smaller than the diameter of the screw.  Mark the center of the screw head to help guide the drill bit.  Start drilling slowly, applying steady pressure.   As you drill, be careful not to damage the surrounding material.  Once you've drilled through the screw, you can use pliers or other tools to remove the remaining part of the screw.

6.   Use a Screw Extractor
A screw extractor is a specialized tool for removing broken or stripped screws. There are two main types: left-hand drill bits and spiral extractors.  For left-hand drill bits, you drill into the screw using the left-hand - threaded bit.  As you drill, the bit will start to grip the screw and turn it counterclockwise, removing it from the material.  Spiral extractors are inserted into a drilled hole in the screw.  The spiral shape of the extractor grips the inside of the screw, allowing you to turn it out.

Tips for Success
Take Your Time: Rushing the process can lead to further damage. Be patient and methodical when attempting to remove a worn-out screw.
Protect the Surrounding Area: When using tools like drills or impact drivers, cover the surrounding area with a cloth or cardboard to prevent scratches or damage.
Test Small Areas First: If you're using a chemical solution or a new technique, test it on a small, inconspicuous area first to ensure it doesn't cause any harm.