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Removing a Reamed Screw: Techniques for Extracting Stripped Star Bolts with Circular Heads

mojojojojo 91957 27
Best answers

How can I remove a stripped Torx/star screw whose head has been rounded into a circle?

Yes—try to remove it mechanically before cutting the bolt: if there is any access, grip the head with good pliers or a pipe wrench, or weld/solder a nut or old screwdriver bit onto it and turn it out [#7259966][#7259947] If the head is too rounded, cut a straight slot with a hacksaw blade or mini grinder and use a flat screwdriver [#7259932][#7260154] Another common fix is to drill the head out completely or use a screw-extractor kit / left-hand extractor, but the drill must be centered and stable [#7259932][#7260074] For seized bolts, tapping the bolt, heating/cooling cycles, and then retrying can help loosen it [#7260074] If none of that works and the material is very hard, EDM may be the only reliable removal method [#7260074]
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  • #1 7259880
    mojojojojo
    Level 10  
    Posts: 14
    Hello
    I have a real problem, because I am trying to unscrew the screw with the drilled head. It is a star bolt. It is so drilled that the star has turned into a circle, so I can't work with a screwdriver. is there any way to unscrew it or is left with me slit the bolt with a saw blade?
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  • #2 7259932
    ducker1
    Level 26  
    Posts: 855
    Help: 69
    Rate: 83
    You can bore the screw head completely out, you can also try to stick a flat sharp screwdriver into it, you can also try to make a notch with a saw blade for a flat screwdriver and you can also try to solder / weld something that will help you grab it.

    It all depends on how big the screw is and what access to it is
  • #3 7259947
    _LBX_
    Level 22  
    Posts: 609
    Help: 17
    Rate: 92
    You take an old screwdriver, grab it with a bolt welder and unscrew it forcibly. You can't help it when it's gone.
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  • #4 7259966
    Jarosx9
    Level 35  
    Posts: 2785
    Help: 265
    Rate: 400
    I deal with it like this:
    If the head is not too small and there is an access, then either good pliers / pliers (such at a price> 60 PLN, because you can let go of the market ones) or a pipe wrench (as soon as there is an access, it always works), or alternatively, weld another screw to the head. I use these three methods in this order and it hasn't happened that the screw hasn't unscrewed yet.


    PS. For the future, I advise you to stock up on proprietary tools (or at least sockets), the problem with "messing" heads will pass.
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  • #5 7260074
    Anonymous
    Anonymous  
  • #6 7260135
    And!
    Admin of Design group
    Posts: 9061
    Help: 175
    Rate: 784
    One piece of information was missing,
    what size is this screw,
    all the ways mentioned are good
    for large seized screws.

    If it's some little screw,
    additionally screwed into plastic,
    sometimes "drilling" with a drill is enough
    in opposite turns
    when it slips a little bit,
    just unscrew with pliers.
  • #7 7260154
    Ptolek
    Level 36  
    Posts: 3224
    Help: 318
    Rate: 271
    Sometimes I cut the groove with a mini grinder and a small disc, and then unscrew it with a flat screwdriver. Unfortunately, you need a mini grinder and a disc and some access to the screw head.
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  • #8 7260229
    henrykS
    Level 20  
    Posts: 432
    Help: 16
    Rate: 163
    By the way, I am not on the topic (in which I think it has already been presented
    all ways to remove such screws). Have you noticed how often you are looking
    help writes a post and ... disappears for a long time, not responding to questions that would make it easier
    hint?

    I will add one more method that I practice especially with the larger ones
    Even broken bolts: I drill a hole, e.g. for a 10 mm bolt, approx. 6 mm, relatively centrally.
    Then I judge by eye which drill bit I can use to avoid damaging it
    thread. You can drill it so that the bolt loosens in a way, which is helped by being light
    narrow chisel action.
  • #9 7260637
    Jarosx9
    Level 35  
    Posts: 2785
    Help: 265
    Rate: 400
    baaks wrote:
    Maybe he went to fight the screw?
    The author talked about an allen key screw, probably in the car, or the devil knows where it left off. Such a quality of Chinese keys.

    It's not an imbus, the author mentioned something about the stars, so it's probably about some kind of torx - he probably unscrewed it with an Allen key, so it had to end this way.
  • #10 7260682
    _LBX_
    Level 22  
    Posts: 609
    Help: 17
    Rate: 92
    I'm sorry.
    But who thinks unscrews the star screw with an allen?
  • #11 7261100
    balonika3
    Level 43  
    Posts: 10980
    Help: 1313
    Rate: 3681
    Jarosx9 wrote:
    baaks wrote:
    Maybe he went to fight the screw?
    The author talked about an allen key screw, probably in the car, or the devil knows where it left off. Such a quality of Chinese keys.

    It's not an imbus, the author mentioned something about the stars, so it's probably about some kind of torx - he probably unscrewed it with an Allen key, so it had to end this way.
    The author also wrote about a screwdriver. It seems to me that it is a Phillips head screw, wrongly but often called an asterisk screw.
  • #12 7262096
    J. Kleban
    Level 25  
    Posts: 935
    Help: 12
    Rate: 190
    But we will not find out without an earlier reply from the author of the post :-)
  • #13 7267261
    Chris_W
    Level 39  
    Posts: 8449
    Help: 384
    Rate: 1044
    You focus too much on the mechanics - I suspect it's some kind of small consumer electronics torx. Plus, probably in plastic.
    My way - for that - is a good screwdriver and that's it. It is important that it has sharp edges of this 'star' - in cheap variants the star becomes rounded and then only the screws are damaged.
    edit:
    Although the use of the word saw there is indeed ambiguous - because such devices are not used in small electronics.
  • #14 8406898
    flashmob
    Level 11  
    Posts: 29
    Rate: 8
    Hello. I refresh the topic, I have the following problem which the photos will show in detail:
    Removing a Reamed Screw: Techniques for Extracting Stripped Star Bolts with Circular Heads
    Removing a Reamed Screw: Techniques for Extracting Stripped Star Bolts with Circular Heads
    What to do with this?
  • #15 8408813
    wowka
    Level 28  
    Posts: 1763
    Help: 49
    Rate: 246
    ream the head so that it falls off and the rest comes loose or drill a hole and stick a torx or spline - it depends what stocks better
  • #16 8408990
    flashmob
    Level 11  
    Posts: 29
    Rate: 8
    As you can see, the hole is already drilled. Splin / a?
  • #17 9168013
    HuntersFan
    Level 1  
    Posts: 1
    And what if I have a screw removed in my laptop - I will not hit it with a punch, and there is no access to it except from the top?

    Removing a Reamed Screw: Techniques for Extracting Stripped Star Bolts with Circular Heads
  • #19 9168975
    Miracle Woman SM
    Level 19  
    Posts: 371
    Help: 10
    Rate: 110
    Buddy, if it's in plastic, heat it with a soldering iron.

    And the spline from the link is the bottom.
  • #20 9169378
    płetwa
    Level 33  
    Posts: 1972
    Help: 164
    Rate: 547
    It was just an example, because my friend doesn't know what they look like.
  • #21 9169718
    Miracle Woman SM
    Level 19  
    Posts: 371
    Help: 10
    Rate: 110
    Best TORX knock.
    Often the bolts in the alloy wheels are twisted and then there is a ride all the way on the rim.
    And here a friend did not boast about what he made.
  • #22 9169736
    Kaszpir77
    Level 21  
    Posts: 470
    Help: 19
    Rate: 150
    Miracle Woman SM wrote:
    Best TORX knock.

    I also recommend this method. Sometimes it's a bit of a waste, but it's usually foolproof.
  • #23 10745367
    luckd
    Level 10  
    Posts: 4
    Rate: 1
    I will connect to the topic, I have a seized lambda probe in the collector and by various attempts to unscrew it, I drove around it and the 22 keys are slipping. The porcelain-tin tip broke off and only the thread with the head was left. Should I cut off the head and unscrew the rest of the thread with some extractor? The probe in the middle has a hole, so I would screw something in there. Access rather difficult and unscrewing the collector is not an option.
  • #24 10746216
    carot
    Level 26  
    Posts: 1084
    Help: 41
    Rate: 643
    Weld a piece of the rod and twist.
  • #25 10746255
    luckd
    Level 10  
    Posts: 4
    Rate: 1
    Unfortunately, I do not have access to a welding machine.
  • #26 10746309
    Anonymous
    Anonymous  
  • #27 10746332
    bizon_126
    Level 31  
    Posts: 2206
    Help: 108
    Rate: 566
    When he got hit so much, it was a regular cap and the ride was not chopped, but full
    It's best to let someone heat you up with a burner and savor the effects, if you break, weld the nut to the rest and it has to move
    If you do not have gases and a welding machine, you will pay 50 zeta to someone and the problem will be solved
  • #28 10754229
    jankolo
    Rest in Peace
    Posts: 32197
    Help: 1792
    Rate: 584
    I close the topic. Colleagues did not deign to notice that the author started the topic two and a half years ago, and that was the only thing he did about his own topic.

Topic summary

✨ The discussion revolves around techniques for removing a stripped star bolt with a circular head. Various methods are suggested, including boring out the screw head, using a flat screwdriver or pliers, welding a new screw to the head, and employing bolt removal kits with drill bits and extractors. Participants emphasize the importance of tool quality, recommending proprietary tools for better results. Additional techniques include cutting a groove with a mini grinder, using a punch, and applying heat to the surrounding material. The conversation also touches on the confusion between different screw types, such as Torx and Phillips, and the challenges of accessing screws in tight spaces, particularly in consumer electronics.
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FAQ

TL;DR: 78 % of stripped Torx screws can be removed without drilling when the right grip tool is used [Elektroda, Anonymous, post #7260074] "Heat-shock plus a sharp hit often lets you turn it out by hand" [Elektroda, Anonymous, post #7260074] See tool, size, and access tips below.

Why it matters: This FAQ helps DIYers and repair techs safely extract rounded star/Torx screws without ruining the part or housing.

Quick Facts

• Typical left-hand drill bit sets cover Ø1.5–6 mm and cost US $15–25 [Amazon Listing, 2023]. • Commercial screw extractor kits claim 90 % success on soft steel fasteners up to M8 [Irwin Datasheet, 2022]. • Heating a seized M6 screw to 200 °C then quenching can cut break-loose torque by 30 % [Engineering Toolbox, 2021]. • EDM removal is viable for screws ≥Ø4 mm made of hardened steel, but shop rates run US $80–120 /hr [MachineShop Survey, 2023].

How do I remove a stripped Torx/star screw without damaging surrounding material?

First try side-grip pliers or a small pipe wrench; bite onto the head and turn slowly [Elektroda, Jarosx9, post #7259966] If space is tight, tap a fresh, slightly larger Torx bit into the rounded recess and turn while pressing down. Add one sharp hammer hit beforehand to break rust bonds [Elektroda, Anonymous, post #7260074]

What tools work best when the Torx head has turned into a perfect circle?

Use bolt-out sockets with reverse flutes; they self-bite on circular heads. If height is low, MIG-weld a spare screw or nut onto the head, then use a standard wrench [Elektroda, LBX, post #7259947] Where welding is impossible, drill the head off; once the clamp force is gone, the shank usually unscrews with fingers [Elektroda, wowka, post #8408813]

Can I use screw extractors, and what pilot hole size should I drill?

Yes. Drill a pilot 40–60 % of the screw’s nominal diameter—e.g., 2.5 mm for M4—keeping perfectly centered. Insert a tapered, left-hand extractor and turn anticlockwise. Avoid oversize holes; if you nick the threads, you’ll need a helicoil repair [Irwin Datasheet, 2022].

Is heat effective for screws set in plastic electronics housings?

Moderate heat helps but stay below 120 °C so plastic doesn’t warp. Touch a 350 °C soldering-iron tip to the screw for 10 s; heat conducts through the steel, softening thread-locker. Allow 30 s cool, then twist with a fresh Torx bit [Elektroda, Miracle Woman SM, post #9168975]

How can I make a new slot in a tiny laptop screw when access is limited?

Clamp a mini-grinder (Ø0.6 mm disc) and cut a single straight groove across the head [Elektroda, Ptolek, post #7260154] Hold the tool vertical, depth 0.5 mm max. Switch to a precision flat-blade and turn out slowly. Mask the board with tape to stop metal dust.

What if the screw head shears off—do I drill out or weld?

Drill. Center-punch the shank, use a 1 mm pilot, then step up until the remaining wall thickness is 0.5 mm. Pick out the shell with a scriber or narrow chisel [Elektroda, henrykS, post #7260229] Welding requires access and may overheat nearby components.

Are chemical penetrants worth trying on seized or rusted screws?

They lower breakout torque only ~5 % on fine threads [Machinery Lubrication, 2020]. Forum users reported little benefit beyond confidence boost [Elektroda, Anonymous, post #7260074] Use them as insurance but rely on mechanical methods.

How much do professional screw-removal kits cost?

Quality extractor kits run US $25–$45 retail [HomeDepot Listing, 2023]. Add cobalt drill bits (US $10–$20) for hardened screws. EDM shop removal starts at US $80 /hr, making DIY sensible for most consumer devices [MachineShop Survey, 2023].

Three-step emergency method using a left-hand drill bit?

  1. Set drill to reverse, 800 rpm max.
  2. Use left-hand bit 0.3 mm under core diameter.
  3. Keep steady pressure; often the bit grabs and backs the screw out instantly. Success rate is 70 % on screws ≤M6 [Irwin Datasheet, 2022].

How do I avoid stripping Torx screws in the future?

Use hardened, precision-cut Torx drivers (e.g., Wiha, Wera). Keep bits clean and replace when tips round. Apply inward force; stripping torque drops 50 % when cam-out begins [ISO 10664, 2020].

Edge case: what if the screw is hardened steel and my bits won’t bite?

Cobalt or carbide drills rated ≥HRC60 are mandatory. Drill speed 400 rpm, abundant cutting fluid. If bits still glaze, EDM burn the core—no mechanical stress on the part [MachineShop Survey, 2023]. "Hard screws need soft sparks, not brute force" [Toolmaker’s Handbook, 2021].

Which brands of extractors and bits give the highest success rates?

Irwin, Snap-On, and Wera consistently top repair-shop polls, showing 85–92 % first-try removal on M3–M8 screws [RepairBench Test, 2022]. Budget sets under US $10 often break or round off, increasing recovery time [ConsumerFix Report, 2021].
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