How to remove a hexagon head screw?

Hexagon head screws (also called hex bolts or hex head screws) are common fasteners used in machinery, furniture, and construction. Their six-sided design provides good torque transmission, but they can become stuck due to corrosion, overtightening, or damage. Here's a comprehensive guide to removing hexagon head screws effectively.

Tools You'll Need
Before attempting removal, gather these tools:

Hex keys/Allen wrenches (standard or metric sizes)

Socket wrench with hex bit

Adjustable wrench or spanner

Pliers (locking or adjustable)

Screw extractor set (for stripped screws)

Hammer

Penetrating oil (WD-40, Liquid Wrench)

Heat source (propane torch for stubborn cases)

Rubber mallet

Drill (as last resort)

Step-by-Step Removal Process
1. Select the Correct Tool
Choose a hex key or socket that fits perfectly. An ill-fitting tool will strip the screw head. Metric and standard (SAE) hex sizes are different - verify which you're dealing with.

2. Apply Penetrating Oil
If the screw is rusted or stuck:

Apply penetrating oil to the screw head and threads

Let it soak for 15-30 minutes (reapply if necessary)

Tap the screw head gently with a hammer to help oil penetrate

3. Attempt Standard Removal
Insert the hex tool fully into the screw head

Apply downward pressure while turning counterclockwise

Use a wrench on the hex key for extra leverage if needed

4. Alternative Methods for Stubborn Screws
A. Improved Grip Methods:

Place a rubber band over the head before inserting the hex tool

Use a torx bit that's slightly larger than the hex socket

Try a star-shaped screw extractor bit

B. Heat Application:

Carefully heat the surrounding metal (not plastic) with a torch

The expansion/contraction can break corrosion bonds

Allow to cool slightly before attempting removal

C. Mechanical Methods:

Use locking pliers on the screw head if enough protrudes

Hammer a slightly oversized torx bit into the hex socket

Create a slot with a Dremel tool for a flathead screwdriver

5. Drilling Out (Last Resort)
If all else fails:

Use a left-hand drill bit (often removes the screw while drilling)

Start with a small bit and increase size gradually

Stop before damaging the threads in the receiving material

Use an easy-out extractor after drilling a pilot hole

Preventing Future Problems
Always use the correct size hex tool

Clean screw heads before attempting removal

Apply anti-seize compound during installation in corrosive environments

Don't overtighten - follow torque specifications

Replace damaged screws immediately

Safety Considerations
Wear eye protection when using extractors or drilling

Be cautious with heat around flammable materials

Secure the workpiece to prevent movement

Keep tools in good condition to prevent slippage

With patience and the right approach, even severely stuck hex head screws can be removed. The key is to start gently and escalate methods gradually to avoid damaging the fastener or surrounding material.