Key Steps
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Wear protective gear while you remove rusted screws, especially when using hammers or blow torches
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Use rust penetrant and a hammer to loosen a rusty screw
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If all else fails, heat with a blow torch, cooling once it smokes with cold water to loosen it enough to use a screwdriver for removal
Trying to remove a rusted, stuck screw? The rough surface and expansion of the rust makes it hard to get them out, even using a screwdriver. Here we’ll show you how to remove rusted screws and replace them safely.
Think you can’t save a rusty screw? Think again! Soak it in a white vinegar and baking soda solution before scrubbing it clean: good as new and ready to use.
How to stay safe when you remove a rusted screw
When you’re removing rusted bolts and screws, it is important to take some key safety precautions.
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Always wear protective gear. This should include gloves as well as eye goggles and a surgical mask to prevent you from breathing in rust particles if they come loose as you remove the screw.
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Take care when using strong rust removal products. Always follow the manufacturer’s instructions, and work in a well-ventilated area. Otherwise, you can learn how to use homemade rust removers to ensure that you’re only handling safe products.
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If you’re using heat to remove the rusted screw, wear leather gloves and ensure there is a fire extinguisher to hand in case of an emergency.
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Make sure children and pets are kept well away from the place where you are working to remove the screw.
4 hacks for rusty screw removal: remove a stuck screw with our simple guide
Here are our top hacks for how to remove a stuck screw that’s crusted up with rust:
1. Use a hammer and screwdriver to remove a rusted screw
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Wear gloves to protect your hands if you slip, and goggles and a surgical mask in case of rust shards or particles which may come loose during this process.
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Strike the screw 2-3 times with a metal hammer. This will break the rust seal causing the screw to be stuck.
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Spray on a commercial rust penetrant. This will soak the screw and help to loosen the rust and act as a lubricant.
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Using the hammer, tap the screw a few more times, and the area around the screw too.
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Using the screwdriver (ensuring it is the right one for the screw type) you should now be able to remove the screw.
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If it is still stuck, use a gripping paste to keep your screwdriver in place. Always follow the manufacturer’s instructions for products such as these.
2. Removing rusted bolts and screws with heat
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Use a water-based degreaser to wipe down the screw.
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Make sure the area is fully cleaned, as you do not want anything flammable going up in flames unexpectedly.
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Wear leather gloves and keep a fire extinguisher close by.
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Heat the screw using a blow torch until it begins to smoke.
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At this point, add cold water immediately.
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Repeat this heating and cooling process 2-3 more times. The heat makes the screw expand, the cold causes it to contract and together they help the screw to become loose.
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Once you have checked the screw is cool enough to touch after this process, use a screwdriver to remove it.
3. Use extractor or locking pliers
If you’ve tried using a screwdriver to remove a rusted screw, you can also try locking pliers to grasp the head and turn the screw out. Also, if the screw head is already broken, you can also use the pliers to grasp its shank.
For this method, it’ll be easier to extract the rusty screw if you buy a pair of extractor pliers. They have grooves that run vertically and horizontally. Because the vertical grooves will let you grasp the pliers upright instead of sideways, it will be easier for you to manage the rusted screw removal.
4. Rubber band hack
Another hack for rusted screw removal is using a rubber band. This approach uses the friction between the screw and the rubber, allowing you to get a good grip on the head. Here are the steps:
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Choose a flat, flexible and wide rubber band. Ideally, the band should be a little bit larger than the screw head.
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Put the rubber band over the stripped screw head. Also, ensure that the rubber is covering the entire surface.
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Use your screwdriver to press firmly on the rubber band. Remember to use a screwdriver that matches the design of the screw head (Phillips or flat head).
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Turn the screwdriver counter-clockwise slowly while applying pressure. The screw head should loosen as the rubber band grips it.
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Keep on turning the screwdriver until you’ve removed the rusty screw.
If the screw won’t budget, you can use multiple layers of rubber bands to create more greep. You can also use a metal-cutting disk to deepen the screwdriver slot.
With our guide for how to remove a stuck screw, you now have all the steps you need to be able to remove and replace them safely. Plus, if you’ve got the DIY bug, why not try some of our easy furniture restoration project ideas? And if you happen to get dirty while removing a rusty screw, follow our guide on how to get rust stains out of clothes
