An Easy Guide to Removing a Rusted Screw

Rusty screws are the bane of any builder's existence. They’re like trying to unscrew a jar lid that just won’t budge (and crumbles when you touch it.)

But, unfortunately, rusty screws are impossible to avoid; you're likely to deal with them from time to time. So, knowing how to safely and effectively remove them so you don’t spend hours on one small task will completely change the game for you. 

With our guide (plus a dash of elbow grease and a can-do attitude), you can take on any rusty screw in your path with a variety of methods. 

Safety First!

Before we dive in, you must keep your eyes protected at all times with safety glasses and use protective gloves when working with sharp tools.

This will prevent injury and help you avoid getting any debris in your eyes. A dust mask is also recommended to stop you from inhaling any rust particles. 

Gather your tools

Once you’ve made the necessary moves to protect yourself, gather the following:

  • Screwdriver (make sure it matches the screw head type)
  • Pliers (locking or adjustable)
  • WD-40 penetrating oil
  • Hammer
  • Screw extractor kit
  • Drill 
  • Wire brush

Optional

  • Impact driver (for extra torque)
  • Sandpaper (to clean rusted areas)
  • Lubricating paste (to prevent future rust)
  • Rubber mallet (to tap the screw out)
  • Centre punch (when using heat)

1. Apply the Oil 

Lubricating the rusty screw with oil helps to simplify the removal process, reducing corrosion and friction. 

WD-40, PB blaster, or liquid wrench is excellent for breaking down rust and loosening the hold on the screw. Choose the best option for you and apply a generous amount over the head and threads of the screw (top tip: tilt the screw so the oil seeps over the whole surface).

But don’t go too far by making it too slippery to hold! Oil can stain porous surfaces like wood, so it’s best to work neatly and precisely to avoid damage. 

Allow the oil to sit on the screw for 15 to 30 minutes, tapping it gently with a hammer to force the oil to soak the threads. If the screw head is flush with the surface, sometimes a little TLC is needed. For this, use a small chisel or flathead screwdriver and hammer to lightly tap the edges to remove any rust.

Then, try to remove the screw using a screwdriver with steady pressure. If that still proves difficult, apply more oil and repeat. Don’t let the screw strip!

2. Use a Screwdriver or Pliers 

Screwdriver

When removing a rusted screw, success lies in choosing the right tools for the application. 

If you’d prefer to go down the screwdriver route, make sure that you choose the right size and type for the screw. A Phillips head screwdriver needs to fit perfectly with the criss-cross pattern of the screw for secure and clean removal. 

For flathead screws, the screwdriver must fit the width of the slot to avoid slipping from a loose hold and damaging the surface. Vertical screws will benefit from a magnetic screwdriver, making it easier to grip and unscrew. 

To cleanly remove the rusty screw, align the screwdriver with the head, keeping it straight. Apply firm and steady pressure downward and rotate in a counterclockwise direction to slowly remove the screw. If it still won’t give up, switch to an impact driver for an extra boost of power.

Pliers

Rusty screws can become too worn down, stripped, or protrude from the material too much to grip. That’s where a good old pair of pliers comes in handy!

Now, there are three different options to choose from:

  • Locking pliers: These grip tightly onto screw heads, ideal for stubborn screws.
  • Needle-nose pliers: Provide extra help for small screws or screws lodged in tight places (don’t use them for helping with heavily rusted screws.)
  • Adjustable pliers: Their wide jaw offers an excellent grip for larger screws. 

When using pliers, you’ll need a firm grip and a steady hand. Place the pliers around the screw head, as close to the base as possible, and turn the screw counterclockwise (apply consistent pressure).

If you experience some resistance, lightly rock the screw back and forth with the pliers to try and dislodge it from the material. The pliers may start to lose grip, but just reposition them and try again! 

If the screw head is stripped or broken, locking pliers will be your best bet.

3. Use a Screw Extractor Kit

For those pesky screws that have been damaged and won’t dislodge with a normal screwdriver or pliers, a screw extractor kit is bound to help. 

This specialised tool can remove screws with broken or stripped heads by drilling into the screw and providing a strong grip for removal. Firstly, select the bit with the right diameter for your screw and use a nail or centre punch to mark the centre of the screw head. 

Then, select the correct drill bit size for the extractor bit and drill slowly into the centre of the screwhead to create a shallow hole. Drill deep enough for a firm grip (but don’t go too far down!)

Insert the extractor bit into the pilot hole until it fits securely, and attach the T-handle to the extractor kit (if included in the kit). Once that’s done, turn the extractor counterclockwise, applying steady pressure, until the screw begins to loosen. When its loose enough, use pliers or a screwdriver to remove.

4. Use Heat

If nothing else is working, heat is the perfect last resort. It will always come through for you. 

This will expand the metal of the screw, breaking the bond with the material and making it easier to remove. However, using heat can lead to a range of other issues popping up, such as igniting remaining rust penetrant, removing the steel’s temper, and melting internal plastic components. 

So it’s best to save this option to last until it's necessary. A heat gun is best if working in a small environment with flammable materials nearby. If not, a propane torch is effective when removing heavily rusted screws from concrete or metal.

When using heat, remove any flammable objects and open all windows and doors for ventilation. Then, heat the screwhead with your chosen device for 1 to 2 minutes until it's warm enough to expand (without overheating). Allow the screw to cool for a few moments, then apply penetrating oil. 

You now should be able to easily remove the screw with pliers or a screwdriver, twisting in a counterclockwise motion.

Further Tips

  • Invest in specialised tools like impact drivers and screw extractor kits if you deal with rusted screws often.
  • Use the rubber band trick for screws with partially stripped heads (this includes placing a thick rubber band or a strip of steel wool over the screw head before inserting the screwdriver).
  • Protect wooden surfaces from damage by placing down masking tape around the screw when using heat, oil, or a screw extractor kit.

Choose Efixings for all of Your Screw Needs

When you choose Efixings for your screws and fixings, you can say goodbye to dealing with rusty screws and weak structures. 

At Efixings, we offer a wide range of high-quality screws, fasteners, and tools to make your job a lot easier. Our stainless steel screws offer excellent rust resistance, perfect for both indoor and outdoor applications. 

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