Broken screw removal

Jun 12, 2019
59
211
West Malling Kent
Funster No
61,597
MH
Pilote G740
Exp
2020
Hi folks
Any one got any suggestions on how to remove a broken screw. The culprit is one of the screws on the window stay bracket, see photos? It snapped flush with the frame so there’s nothing to get hold off with long nose pliers. I’ve looked at screw extraction sets, but they all require you to drill a hole in the broken screw. Can’t see how i’d get started on the 3-4mm that is visible, any suggestions?
Thanks in advance😁
 

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Looks like a hardened steel self-tapper, is that right?

If so, drilling might be a bit of a challenge but if you could start with a 1mm bit and work progressively larger, you might be able to remove the main shank of the screw and eventually the threaded part can be wound out or peeled away.

Alternatively, if you have a Dremel-type tool, try using a cut-off wheel to carefully cut a slot in the screw that will take a flat-blade 'driver.

Hopefully all the witness marks will be behind the bracket when you replace it.

Good luck!
 
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Ooh, you're gonna struggle with that. I think you're gonna have to offset the stay bracket a little bit and drill two new holes, maybe sandwich a piece of same colour plastic as the catch or a thin piece of aluminium to cover the existing holes ?
 
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Can you remove the frame? If so you might have enough material to get hold of with pliers or pincers.
 
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I cant see too clearly your pic the mm width but this set has brought a few out for me without drilling holes, and one where I put a small pilot about 3 mm deep, I put pressure on it and it self drills a tiny bit.
Amazon product ASIN B01E9ZC2K2

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I think drill new holes a little lower but if the are the type of arms that click to lock, you would have to do both sides
 
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Put a good covering of masking tape to protect from scratches if the drill bit slips, the tape will also help to hold the drill bit in place.
 
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Just from my own experience, my ratchet stays started causing problems replaced a couple then gave up on them, have replaced them all with locking thumb screw type. Holes are in slightly different distance apart and have to re drilled.
 

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If you've got a few mm sticking out, you might be able to use a drill collar or a bit of tubing that just fits over the screw to centralise the drill bit to get you started.

Alternatively, as it appears to be going in to thin metal with a void behind it, you may be able to gently tap it on one edge with a sharp punch to either rotate it in or out (tapping at right angles to make it rotate, not bashing it straight on to force it through).
 
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I cant see too clearly your pic the mm width but this set has brought a few out for me without drilling holes, and one where I put a small pilot about 3 mm deep, I put pressure on it and it self drills a tiny bit.
Amazon product ASIN B01E9ZC2K2
Those are good but I've used them on stainless screw not sure if they would work on a hardened self-tapper.

The metal is only thin you may be able to punch the screw through then fit the next size screw or a rivnut or cavity fixing.
 
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Hi folks
Any one got any suggestions on how to remove a broken screw. The culprit is one of the screws on the window stay bracket, see photos? It snapped flush with the frame so there’s nothing to get hold off with long nose pliers. I’ve looked at screw extraction sets, but they all require you to drill a hole in the broken screw. Can’t see how i’d get started on the 3-4mm that is visible, any suggestions?
Thanks in advance😁
Get hold of a small centre drill, they have a point drill at each end with a short shank between which do not flex. The smaller the better to give you a chance of getting the drill part dead centre. They are intended for drilling on a lathe but a hand electric drill in your case will do
1656617722316.png
This is what they look like. About £2.00 and sorry forgotten what the sizes are for them. Do a google for Centre drill
 
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Thanks for all the replies guys, I’m fairly sure they are hardened steel screws. I’m got in to get one of the screw extraction kits as show by Tombola. If it does’nt work then I’ll change the position of both of the window stay fixing bracket. May even change to the locking thing screw type as I do prefer these.

thanks again for all the replies👍

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Upvote 0
Thanks for all the replies guys, I’m fairly sure they are hardened steel screws. I’m got in to get one of the screw extraction kits as show by Tombola. If it does’nt work then I’ll change the position of both of the window stay fixing bracket. May even change to the locking thing screw type as I do prefer these.

thanks again for all the replies👍
If you end up trying to drill it , be sure to use a centre punch first.
Gl with getting her out :)
 
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Can anyone recommend what screws to ? I need to repair a a couple of our window stays...I've drilled new pilot holes (the previous screws are still sheared off in the old holes and I can't get them out) but I can't find any screws strong enough to tap into the frame....the new screws just keep breaking off too :(

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If the new screws are decent but continue to break each time are you sure your pilot holes are big enough?
 
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