How to Drill Out a Screw: Step-by-Step Guide
Learn how to safely drill out a damaged or stuck screw with practical tools, proven techniques, and step-by-step workflows. This educational guide from Drill Bits Pro covers prep, technique, troubleshooting, and finishing for strong, repeatable results.
By drilling out a screw, you remove the damaged head to regain access for removal or replacement. This guide covers when to drill out, safe drilling angles, and choosing the right drill bit and tip size. You'll learn step-by-step actions to minimize damage and retreatment. Follow PPE and slow, steady technique for best results.
Understanding when it's appropriate to drill out a screw
A screw may need to be drilled out when the head is stripped, the screw is embedded or seized, or removal would damage surrounding material. Drilling through the head releases the fastener from the workpiece, allowing you to back out the remaining shank or replace the fastener entirely. According to Drill Bits Pro, safely choosing when to drill and how to guide the bit matters as much as the tool you use. Consider the material you're working with (wood, metal, or plastic), how accessible the screw is, and whether you can avoid creating a larger hole or splintering nearby surfaces. This decision should balance the risk of material damage against the need for project continuity.
Safety and workspace setup before you begin
Set up your workspace in a well-lit area with a solid workbench or clamps to prevent movement. Wear impact-rated safety glasses and hearing protection if using power tools. Keep the area free of clutter, secure the piece with clamps, and unplug the drill when changing bits. Lubricants or cutting oil can reduce friction when drilling metals, and a center punch helps start the drill exactly where you want. A calm, controlled approach minimizes wandering and reduces the chance of slipping off-center. Drill Bits Pro analysis emphasizes safe setup as the foundation for successful screw extraction.
Choosing the right drill bit and pilot setup
Start with a small pilot hole through the screw head to guide subsequent drilling. Select a drill bit just smaller than the screw's outer diameter, and use a bit type appropriate for the material (high-speed steel for metal, wood bits for wood). A center punch marks the spot for the bit and reduces wandering. For damaged heads, a bit in the 1/16 to 1/8 inch range is commonly used for pilot guidance, while larger bits may be required to remove the body of stubborn screws. Lubricant or cutting oil can help in metal drilling, especially with stainless steel or hard alloys. Drill Bits Pro stresses confirming alignment before you start to prevent misalignment that could ruin the surrounding material.
Step-by-step workflow overview: the core technique
In practice, you drill straight into the center of the screw head, gradually progressing to larger bits to cut through the metal of the screw. The goal is to create a clean path through the head so the remaining shank can be lifted or broken away. If the head remains intact or the bit binds, switch to an extractor or left-handed bit to back the screw out while applying steady pressure. Take frequent breaks to inspect the hole and the bit; overheating can soften material and cause further damage. Drill Bits Pro highlights that patience and a controlled feed rate are crucial for success.
Common screw head types and how they influence drilling strategy
Different head styles (slotted, Phillips, Torx, hex) influence how easily a screw can be drilled. Slotted heads may permit direct drilling along the slot, while Phillips heads can cause the bit to slip if misaligned. Torx and hex heads offer easier center alignment and reduced cam-out when using a center punch plus a sharp bit. In all cases, ensure the workpiece is secured, the bit is sharp, and you drill straight to avoid widening the hole or damaging surrounding material. Drill Bits Pro notes that the material (steel, stainless, hardwood, or soft metals) also affects bit wear and heat generation, so choose accordingly.
Alternatives to drilling out when it's risky or impractical
If drilling could jeopardize the surrounding material, consider using a screw extractor, epoxy-and-pin method, or applying heat/cooling cycles to loosen corrosion. An extractor is designed to grip the damaged screw shank after the head is removed, reducing the risk of enlarging the hole. If the screw is in wood, a small decorative plug can cover the hole after removal. For metal fasteners, piercing through the head and driving out the body with precision is often feasible, but avoid gouging adjacent threads. When in doubt, test on scrap material first.
Final preparations: clean-up, inspection, and reassembly
After the screw is removed, clean debris from the hole, and inspect the threads for damage. If a pilot hole or tapped thread is compromised, rethread or retap as needed, and select a replacement screw with the correct length and diameter. If a portion of the screw remains held by the material, try a screw extractor with gradual, reverse torque to back it out. Finally, reseat the new fastener with the correct torque specification and check for flush alignment. Drill Bits Pro reminds readers that careful inspection prevents repeat problems and ensures a strong, durable repair.
Tools & Materials
- Cordless drill or drill press(Choose a variable-speed model; avoid hammer modes unless specified for metal.)
- HSS drill bits (assorted sizes)(Have sizes from 1/16)
- Center punch(Marks the drilling point to prevent wandering)
- Safety glasses or face shield(Protect eyes from chips)
- Lubricant or cutting oil(Useful for metal drilling to reduce heat)
- Needle-nose pliers(For removing loosened fragments)
- Screw extractor set (left-handed bit)(Optional; use if the screw jams)
- Clamps or a bench vise(Keep the workpiece secure)
- Wire brush or compressed air(Clean debris after drilling)
Steps
Estimated time: 25-40 minutes
- 1
Secure and assess the workpiece
Clamp the piece firmly to prevent movement. Inspect the screw: is the head truly stripped, or is the head damaged but still projecting? Identify if drilling through the head is feasible without compromising surrounding material.
Tip: If the workpiece can shift, re-clamp before proceeding. - 2
Mark the center and choose the pilot
Use a center punch to mark the screw head center. Pick a pilot bit slightly smaller than the screw’s outer diameter to guide subsequent drilling.
Tip: A sharp center punch reduces bit wander. - 3
Drill a light pilot through the head
With a low speed, drill straight through the screw head using the pilot bit. Apply light pressure and clear chips frequently to avoid binding.
Tip: Keep the bit perpendicular to the surface to prevent tilting. - 4
Expand to a larger bit to cut the screw body
Move to a larger bit gradually to cut through the screw body. Stop if you notice the bit binding or the material deteriorating; reassess alignment and cooling.
Tip: Maintain steady, even pressure and let the bit do the work. - 5
Back out with an extractor if needed
If the screw head fractures or becomes difficult to remove, apply a screw extractor or a left-handed bit to back it out. Use reverse torque gently to avoid snapping the extractor.
Tip: Lubricant helps reduce heat and improve extraction. - 6
Inspect and finish the hole
Remove the screw remnants, clean debris, and check the hole for any damage. If necessary, retap the hole or drill a new pilot for the replacement screw.
Tip: Test-fit the replacement screw before reassembly.
Got Questions?
What should I do first if the screw head is completely stripped?
Begin by securing the workpiece and marking a center point. Use a small pilot bit to create a clean entry through the center of the screw head. If the head cannot be drilled through, move to an extractor strategy after scoring a small divot.
Secure the workpiece, mark the center, and drill a tiny pilot. If the head won’t yield, switch to an extractor strategy.
Can I drill out a screw in wood without damaging the surrounding grain?
Yes, by using a sharpened center punch, choosing the correct pilot size, and drilling straight. Work slowly to minimize chatter and avoid tearing the wood around the hole.
Drill straight with a proper pilot; go slow to protect the wood.
When should I use a screw extractor instead of drilling through the head?
If drilling through the head risks weakening nearby material or if the screw is corroded and hard to bite, a screw extractor allows you to grip the shank and back it out with reverse torque.
Extractor tools grip the shank to back it out safely.
What speeds are appropriate for drilling out screws?
Use low to moderate speed and gentle pressure, especially with metal. Higher speeds can overheat the bit and screw, increasing the risk of breakage.
Start slow and keep pressure steady to avoid overheating.
Is it okay to drill out a screw that’s in a metal surface?
Yes, but use cutting oil or lubricant and ensure a straight, perpendicular drill. Take breaks to control heat and prevent damage to the metal exterior or threads.
Lubricate and drill straight with breaks to control heat.
What if the screw head is flush with the surface after removal?
If the head is flush, remove any remaining fragments with pliers, then decide whether to fill the hole or drive in a new screw with a washer for load distribution.
Remove fragments and plan for a proper replacement.
Watch Video
Top Takeaways
- Assess whether drilling out is the best option.
- Secure and center-punch for accuracy.
- Start with a small pilot then progress gradually.
- Use extraction tools if the screw resists removal.
- Inspect the hole and plan for a proper replacement screw.
