Suggestions—> Broken Screw

[Sage1]

I was cleaning up the slotted screws on a TC Hawken patch box today and likely weekend the screw head. One half of the flat part of the screw head broke off. Sometimes I guess it’s best to leave well enough alone.
Likely I’m not the first guy to do this so I’m looking for ideas on how to extract the screw w/doing damage. It’s not a large screw so drilling it and using an Extractor/EZ Out may not be possible.
Really I don’t know , maybe they do make small extractors.
Any suggestions are appreciated. Thanks.

 

[TDM]

I don't have my set of EZ Outs with me, but one of them is pretty small. Worth checking around to see if you can find the correct size. Another option would be to a reverse cut bit in the correct size.

 

[Sage1]

I don't have my set of EZ Outs with me, but one of them is pretty small. Worth checking around to see if you can find the correct size. Another option would be to a reverse cut bit in the correct size.

Thank you.
I’m not familiar with a Reverse Cut Bit.
But you gave me an idea. Assuming the patch box comes off. Dremel a slot in the top of the screw post and unscrew it. Taking a break from it for a bit. Will get back on it.

 

[user 34300]

Those screws are very small. There are no such easy outs. I would try heating the broken screw enough with a soldering iron to burn the wood a little. That may loosen it enough to back it out with half a head.

If that fails I'd carefully remove the rest of the head with a tiny carbide dremil bit. Remove the patch box. Grab the busted screw with pliers or a pin vice if possible. IF not I'd remove it with a plug cutter. Then replace the wood with a plug. Then install a new screw.

 

[The Crisco Kid]

Ditto on the plug cutter if nothing else works. I've done it myself. The main thing now is, don't get in a hurry!

 

[Commodore Swab]

Try a punch/small chisel on the remaining half, either it will turn or break off. If it breaks off remove the patch box and cut a slot in the remainder leaving a small cut in the wood. Unscrew it. Provided of course it wasnt put in with epoxy . . .

 

[OldRust]

Those brass screws like to break. I have carefully ground the remaining 1/2 of the broken screw head off with a dremel tool, removed the other screw and patch box. You will then be able to remove the broken screw shank with a good pair of plyers or small vice grips.

Thanks,
O.R.

 

[Mgbruch]

When you do get it out, you might consider replacing them with steel screws.

 

[Sage1]

I was cleaning up the slotted screws on a TC Hawken patch box today and likely weekend the screw head. One half of the flat part of the screw head broke off. Sometimes I guess it’s best to leave well enough alone.
Likely I’m not the first guy to do this so I’m looking for ideas on how to extract the screw w/doing damage. It’s not a large screw so drilling it and using an Extractor/EZ Out may not be possible.
Really I don’t know , maybe they do make small extractors.
Any suggestions are appreciated. Thanks.

View attachment 307960

Thank you all for the ideas. What worked was drilling a very small hole right on the edge of the slot. The brass was soft enough where the bit stayed in place. Enlarged it and then a #1 EZ Out extractor backed the screw easily. No collateral damage.
Thanks again for the assistance.

 

[Rhacknc]

I was cleaning up the slotted screws on a TC Hawken patch box today and likely weekend the screw head. One half of the flat part of the screw head broke off. Sometimes I guess it’s best to leave well enough alone.
Likely I’m not the first guy to do this so I’m looking for ideas on how to extract the screw w/doing damage. It’s not a large screw so drilling it and using an Extractor/EZ Out may not be possible.
Really I don’t know , maybe they do make small extractors.
Any suggestions are appreciated. Thanks.

View attachment 307960

Thank you for posting this. Same exact thing happened to me on my TC Hawken, only difference it was the opposite end screw. I had some corrosion on the patch box and wanted to take it off to clean it and darn thing just flaked off. I have not attacked mine yet, but now have something to go on.

 

[Phil Coffins]

Steel screws work well and are more old-timey.
IMG_0822 by Oliver Sudden, on Flickr

 

[Sage1]

Steel screws work well and are more old-timey.
IMG_0822 by Oliver Sudden, on Flickr

That darker finish looks good.

 

[planefixer da50]

drop of dish soap,let soak. locate #40 left hand drill bit. granger has them. try a hook scribe to turn from the head half, soap first. use bee wax when installing screws.

 

[Dude]

I've heard that steel screws are historically correct. Glad you got it out with no damage.

When I got my hawken, the head of one of those patch box screws was missing. Of course the shank was still there. Not a big deal, just part of the sweat equity.

 

[James Kibler]

That's why iron or steel screws are period correct.

 

[EC121]

I would have removed the cap box and turned the screw out with small pliers. Or cut a new slot with my Dremel.

 

[RMFnLA]

It can be done.

Here’s a side plate screw I extracted from a friend’s old Colt.

The good news is brass is much easier to drill than steel.

 

[PathfinderNC]

That's why iron or steel screws are period correct.

I guess that’s not much of a concern with Thompson Center

 

[Pete G]

I guess that’s not much of a concern with Thompson Center

T/C is period correct…about the 1975 period.

 

[FlinterNick]

I was cleaning up the slotted screws on a TC Hawken patch box today and likely weekend the screw head. One half of the flat part of the screw head broke off. Sometimes I guess it’s best to leave well enough alone.
Likely I’m not the first guy to do this so I’m looking for ideas on how to extract the screw w/doing damage. It’s not a large screw so drilling it and using an Extractor/EZ Out may not be possible.
Really I don’t know , maybe they do make small extractors.
Any suggestions are appreciated. Thanks.

View attachment 307960

I would cut a slot in it with a small cutting bit on a rotary tool, just do it on slow speeds so the tool doesn’t wander.

On the plus side the area is pretty well hidden once it’s fixed.

I would take extra care into not damaging the rest of the stock while cutting the slot in the screw.