The Ultimate Guide: How to Remove Broken Hex Wrench Like a Pro!

Ever tightened a screw with a hex wrench, only to find it snapped off inside? It’s a frustrating experience, leaving you with a broken tool and a stubborn screw. But don’t despair! This guide will walk you through the steps on how to remove a broken hex wrench, equipping you with the knowledge and techniques to tackle this common mechanical mishap.

Assessing the Situation: What Kind of Break?

Before diving into removal methods, it’s crucial to assess the nature of the break. Understanding the type of break will guide your approach and determine the best tools for the job.

• Clean Break: A clean break leaves a smooth, flat surface. This is the easiest scenario for removal.
• Sheared Break: The wrench has sheared off at an angle, leaving a jagged edge. This requires more careful handling.
• Embedded Break: The broken wrench is completely embedded in the screw head, with no visible portion sticking out. This is the most challenging situation.

Essential Tools for the Job

Having the right tools is essential for successful hex wrench removal. Here’s a list of common tools you’ll likely need:

• Small Pliers: Used for gripping and rotating the broken piece.
• Needle-Nose Pliers: Helpful for reaching into tight spaces and gripping smaller pieces.
• Vice Grips: Provide a strong grip for larger pieces or when more leverage is needed.
• Dremel Tool with Cutting Disc: Used for cutting the broken wrench flush with the screw head.
• Drill with Drill Bits: Used to create a pilot hole for extraction methods.
• Extractor Set: Special tools designed to grip and remove broken fasteners.
• Hammer: Used for tapping the extractor or driving the broken piece out.
• Safety Glasses: Always wear safety glasses to protect your eyes from flying debris.

Method 1: The Simple Twist and Pull

This method works best for clean breaks where a small portion of the wrench remains exposed.
1. Grip the Wrench: Use pliers or vice grips to firmly grip the exposed portion of the broken wrench.
2. Twist and Pull: While applying pressure, twist the wrench counter-clockwise. This will loosen the grip on the screw head.
3. Persistent Effort: Be patient and persistent. It may take some effort to loosen the wrench. If it doesn’t budge, try applying a little heat with a soldering iron or heat gun to the screw head.

Method 2: The Dremel Approach

If the broken wrench is flush with the screw head, a Dremel tool with a cutting disc can be used to create a groove for removal.
1. Prepare the Surface: Clean the area around the broken wrench to ensure a smooth cutting surface.
2. Cut a Groove: Carefully use the Dremel tool with a cutting disc to cut a groove around the broken wrench. The groove should be deep enough to allow for a good grip with pliers.
3. Grip and Twist: Use pliers or vice grips to grip the groove you created and twist the broken wrench counter-clockwise until it loosens.

Method 3: The Extractor Method

For embedded breaks, an extractor set is the most effective solution.
1. Select the Right Extractor: Choose an extractor with a size slightly smaller than the broken wrench.
2. Drill a Pilot Hole: Use a drill bit slightly smaller than the extractor’s diameter to drill a hole into the center of the broken wrench.
3. Insert the Extractor: Screw the extractor into the pilot hole.
4. Apply Pressure: Apply pressure to the extractor, turning it counter-clockwise. The extractor will grip the broken wrench and pull it out.

Method 4: The Reverse Drill Method

This method works best for clean breaks where a small portion of the wrench remains exposed.
1. Select a Drill Bit: Choose a drill bit slightly smaller than the broken wrench‘s diameter.
2. Drill into the Wrench: Carefully drill a hole into the broken wrench, going as deep as possible.
3. Insert a Screw: Insert a screw into the hole you drilled.
4. Twist and Pull: Use pliers or vice grips to grip the screw head and twist it counter-clockwise. The screw will pull the broken wrench out of the screw head.

Preventing Future Breakage

Once you’ve successfully removed the broken wrench, it’s important to take steps to prevent future breakage:

• Use the Right Size: Always use the correct size hex wrench for the screw.
• Apply Even Pressure: Avoid applying excessive force when tightening screws.
• Lubricate the Wrench: Use a light lubricant on the wrench to reduce friction.
• Inspect Tools Regularly: Check your tools for signs of wear and tear. Replace damaged tools immediately.

Time to Move On – A Final Word

Removing a broken hex wrench can be a challenging task, but with the right tools and techniques, you can handle it with confidence. By assessing the situation, choosing the appropriate method, and practicing patience, you can overcome this common mechanical obstacle and get back to your projects. Remember to always prioritize safety by wearing protective gear and working in a well-lit area.

Frequently Asked Questions

Q: What if the broken wrench is made of a soft metal?
A: For soft metal wrenches, using an extractor or drilling a hole may not be effective. You might need to try a different approach, such as using a small chisel to carefully chip away at the broken wrench.
Q: Can I use a hammer to remove the broken wrench?
A: While a hammer can be helpful for driving an extractor or tapping the broken piece out, it should only be used with caution. Excessive force can damage the screw head or surrounding materials.
Q: What if the screw head is stripped?
A: If the screw head is stripped, you’ll need to use a different method for removal. You can try using a screw extractor, a bolt-out tool, or a specialized screw head remover.
Q: What if I don’t have an extractor set?
A: If you don’t have an extractor set, you can try using a small bolt or screw with a head that fits snugly into the broken wrench. Drill a pilot hole into the broken wrench and screw the bolt or screw in. Then, use pliers or vice grips to turn the bolt or screw counter-clockwise to remove the broken wrench.