How to Remove a Stripped Hex Screw: Step-by-Step Methods That Work

Stripped hex screws are one of the most frustrating challenges during repair, maintenance, or assembly work. When the hexagonal socket rounds out, the Allen key or hex bit can’t grip properly, leaving you stuck with a fastener that won’t turn. Fortunately, there are several practical techniques to remove a stripped hex screw without causing damage to your project or tools.

This guide explores why hex screws strip, what tools you can use to fix the problem, and the most effective step-by-step removal methods.

Why Hex Screws Strip in the First Place

Before removing the screw, it helps to understand why it got stripped:

Incorrect tool size – Using the wrong size hex key or bit quickly damages the socket.

Poor-quality screws – Soft metals are prone to rounding under pressure.

Over-tightening – Excess torque deforms the socket.

Angle misalignment – Inserting the tool at an angle instead of straight causes uneven wear.

Knowing these causes helps prevent future issues, especially when working with delicate materials or frequent assembly jobs.

Tools That Can Help Remove a Stripped Hex Screw

Standard Allen keys or hex bits (correct size)

Flathead screwdriver

Rubber band or steel wool

Pliers or locking pliers

Screw extractor kit

Rotary tool with cutting disc

Hammer and punch

Lubricants (WD-40 or similar)

Step-by-Step Methods to Remove a Stripped Hex Screw

1. Try the Rubber Band Trick

Place a wide rubber band (or piece of steel wool) over the stripped socket. Insert your hex key firmly into the screw head and turn slowly. The added friction often provides enough grip to loosen it.

2. Switch to a Flathead Screwdriver

If the screw head is slightly exposed and the socket is wide enough, wedge a flathead screwdriver diagonally into the stripped hex and twist. This works best on softer screws.

3. Use Pliers or Locking Pliers

When the screw head protrudes above the surface, clamp it tightly with pliers and rotate counterclockwise. Locking pliers provide extra stability for stubborn screws.

4. Tap with a Hammer and Punch

Place a punch or even a flathead screwdriver into the socket and tap gently with a hammer. This can break the rust or loosen the threads, allowing you to grip the screw again.

5. Cut a New Slot with a Rotary Tool

If you have a rotary tool, cut a straight groove across the screw head. Then use a flathead screwdriver to turn it out. This sacrifices the screw but saves the project.

6. Apply a Screw Extractor Kit

A screw extractor is a specialized tool designed for stripped fasteners. Drill a small pilot hole into the screw head, insert the extractor, and twist counterclockwise. The spiral flutes bite into the screw and pull it out.

7. Apply Heat or Lubricant

If corrosion is the cause, spray penetrating oil into the threads and let it sit for 10–15 minutes. In some cases, gently heating the screw with a soldering iron or heat gun helps expand the metal, making removal easier.

Preventing Future Stripped Screws

Always use the correct size hex key or bit.

Apply steady, even pressure instead of sudden force.

Avoid overtightening during installation.

Use high-quality screws made from durable alloys.

Keep tools in good condition—worn keys damage sockets more easily.

Final Thoughts

A stripped hex screw doesn’t have to end your project in frustration. From simple tricks like rubber bands to heavy-duty solutions like extractors, there are multiple ways to tackle the problem. Choose the method based on the tools you have on hand and the accessibility of the screw. With patience and the right approach, you can remove even the most stubborn stripped hex screw and prevent future headaches.