Removing Pan Head Screws: A Step-By-Step Guide

Removing pan-head screws can be a challenge, especially if they are stripped or one-way security screws. Here are some methods to help you tackle this task: For stripped screws, using a rubber band, steel wool, or abrasive powder can help increase friction and grip. You can also try a different screwdriver or a larger screwdriver size to fill the voids in the stripped head. A manual screwdriver provides more torque and control than an electric drill, reducing the risk of further stripping. For one-way screws, special extraction tools are now available online and at hardware stores. These tools have steel pins that fit into the slots on the screw head. Alternatively, you can cut a new slot into the screw head using a high-speed rotary tool, effectively turning it into a flat-head screw. As a last resort, you can use locking pliers to create a strong grip on the screw head and turn it out.

How to Remove Pan Head Screws

Using a screwdriver and hammer

Firstly, you will need to place the tip of a flathead screwdriver on the top of the stripped screw. It is important to ensure that the screwdriver is the correct size for the screw. If the screwdriver is too small, it will not be able to grip the screw properly, and if it is too large, it may damage the screw head.

Once the screwdriver is in position, use a hammer to lightly tap the end of the screwdriver handle 2-4 times. This will help the screwdriver dig into the screw head, giving it a better grip. Make sure not to use too much force when tapping, as this may damage the screw or the surface it is embedded in.

After tapping, try to turn the screw counterclockwise to loosen it. If it does not turn, try tapping the screwdriver a few more times and then attempt to turn it again. It may take several attempts to loosen the screw, so be patient and persistent.

Once the screw begins to turn, continue to apply pressure and turn it counterclockwise until it is completely removed. If the screw is difficult to turn, you can try using a pair of pliers to get a better grip and help you turn it more easily.

Using a screw extractor tool

Step 1: Choose the Right Screw Extractor

Select a screw extractor that fits the size of your screw. Screw extractors have two sides. One side is used to create a smooth hole in the screw head, while the other side grips onto the hole and drills it out. Make sure both sides of the screw extractor fit your damaged screw head.

Step 2: Prepare the Screw

If your screw extractor doesn't have a burnishing end, you may need to create space in the screw head for it to work. You can do this by drilling a small hole in the centre of the screw head. This will act as a guide for the screw extractor. Use a drill bit that is smaller in diameter than the screw and drill slowly and carefully to avoid drilling too deep.

Step 3: Use the Screw Extractor

Insert the first side of the screw extractor bit into the damaged screw head. Use your drill in reverse to create a smooth hole. Then, switch to the second side of the extractor bit and insert it into the hole you just made. Continue to use your drill in reverse to grip and turn the screw out.

Step 4: Finish Removing the Screw

Once the screw is loose enough, you can finish removing it with locking pliers. Clamp the pliers onto the screw as close to the wood surface as possible and gently turn it counterclockwise. Work slowly to avoid snapping the screw head.

It is important to prioritise safety when using power tools. Always wear safety glasses to protect your eyes from flying debris and consider wearing gloves to protect your hands from metal shavings.

Using a drill

Drilling is a good option when other methods of removing a screw have failed. If the screw head is stripped and you can't get a grip on it, you can try drilling into the screw head to remove it.

Firstly, try to remove the screw manually. If the screw head and part of the shaft are visible, use a pair of pliers to slowly twist it out. If you can't see enough of the screw to twist it out with pliers, try using a slightly bigger or smaller screwdriver to loosen the screw.

If the head of the screwdriver doesn't catch on any part of the stripped screw, stop. You don't want to make matters worse. Instead, place a large, flat rubber band over the head of the screw and then try to unscrew it with a correctly-sized screwdriver.

If none of these manual tricks work, then it's time to break out the drill. Find a drill bit that is just large enough in diameter to drill out the centre of the screw head. If it's a Phillips head screw, find a bit that just covers the star shape in the centre.

Slowly begin drilling the centre out of the screw head. It should be relatively easy and quick. You don't need to drill too deep, just far enough to disconnect the screw head from the shaft. Usually, the head will start to spin as it separates.

Now that you've drilled out the head, you should be able to remove the part you were working on. With the part off, you can see the stump of the old screw. Grab a pair of vice grips and attach them firmly to the stump. Now slowly unscrew it until the whole thing comes out.

Using pliers

Specialist screw removal pliers, such as the PZ series, have been designed with both horizontal and vertical serrations to generate enough gripping power and friction to easily remove the stuck screw. These pliers are available in a range of models and can be used to cut, crimp, and perform other functions generally performed by traditional multi-purpose pliers.

To use locking pliers to remove a screw with a stripped head, clamp the pliers to the screw as close as possible to the wood surface and gently turn it counter-clockwise. Work slowly to avoid snapping off the head. For screws that are flush or embedded in wood, groove out a couple of shallow indentations next to the screw head to allow for a better grip.

If the screw head stands above the wood, you can protect the wood surface by cutting a small piece of cardboard and sliding the notched halves around the screw. This way, if the pliers slip, the wood will not be scratched.

Using a rubber band

Choose a rubber band that is wider than the screw head. It should be a single, thick rubber band that covers the opening in the screw head. Compare the rubber band to the width of the screw head to ensure it is big enough. If the rubber band is too small, it will not fill the space in the opening, and you will not be able to get a good grip on the screw threads with your screwdriver.

Position the rubber band over the stripped screw. Press part of the rubber band flat against the screw head and hold it firmly in place with one hand. Make sure you have a good grip and are able to keep the rubber band against the metal for a few seconds. If needed, reposition the item with the screw to access it more easily. The entire rubber band does not have to be over the screw. If it is whole, move the excess aside.

Place the screwdriver into the rubber band and screw head. Ensure the rubber band goes inside the opening on the screw head, moulding with the screw threads to create leverage for the screwdriver. Hold the screwdriver steady to keep the rubber band in place. Press down with firm pressure so that the rubber band fits against the threads, but be careful not to break through the rubber band.

Turn the screwdriver counterclockwise to remove the screw. Work slowly, as the screw will still be difficult to turn. While maintaining firm pressure on the rubber band, gradually turn it. You should feel the screw begin to turn and loosen. Reposition the rubber band if necessary and continue until you can remove the screw.

If the screwdriver penetrates the rubber band, move the rubber band over so you can use an unbroken section. Even if you follow these steps correctly, you may not succeed in removing the screw. If this happens, try using other tools, such as a drill.

Frequently asked questions