Another broken screw thread (in wood)

[josrulz]

Hi all,
I saw some old threads on this topic, but they focused more on corroded screws in metal. My problem is a broken screw in wood. Here's the deal:

I'm removing the 10' long handrails on our cabin top. The rest of the screws all came out fine, this is the only one, and it was broken before I got to it. All the screws were under teak bungs (now removed).

So the hole for the teak bung is about 3/4" - 1" deep, so that's where the top of the broken screw is. Then it's screwed into the wood in the handrail, through the deck, and into the core.

Any suggestions?
-J

[2Gringos]

which part of the screw is broken? can you get needlenose Vise Grips on it?

[RocketScience]

Just did this exercise on my P35...

If the head of the screw is broken off, and the rest of the screws have been successfully removed, a slight back and forth rolling action combined with a strong upward pull should free the rail. You will be left with a stud that you can now remove with your visegrips.

[josrulz]

Originally Posted by RocketScience

Just did this exercise on my P35...

If the head of the screw is broken off, and the rest of the screws have been successfully removed, a slight back and forth rolling action combined with a strong upward pull should free the rail. You will be left with a stud that you can now remove with your visegrips.

The only thing I'm concerned about is damaging the hand rail--not worried about the screw hole, just the handrail itself, like cracking or something. I suppose if we're really careful, then we'd be OK...

[bljones]

use a plug cutter bit to cut around the screw, remove the rail and then epoxy in a plug.

[gershel]

Just a longshot, but... What if you bored oround the old screw with a plug cutter, then remove the wood inside the cut, revealing a good bit of the screw shank. Then try to grip it with needle nose vice grips, or if the plug cutter is long enough, bore all the way through to the fibre glass. Then fill the hole with a new plug and epoxy. Lots you can do, use your imagination.
Marc

[gershel]

Sorry, I guess I type too slow. (old)
Marc

[josrulz]

Thanks for the suggestions. I'll see if I can find a plug cutter that's smaller than the existing hole on the outside, but larger than the screw...hmmmm....

[Bene505]

I have a similar situation, but the bolt head broke off nearly flush with the wood surface (the actual interior wood, not the handrail).

I plan on using a dremel to cut a notch into the head of the bolt and then use a regular screw driver to simply un-screw it out. The advantage of this method is that if it comes out ok, then I can use the same hole when I re-install the handrail.

Perhaps you can get one of those vibrating cutters and get the vibrating cutting surface down into the hole far enough to cut a slot in the broken screw. Adding 3 parts patience, of course.

And you can use the vibrating tool for other things afterwards too. Like relieving that shoulder pain from all the work you are doing.

Regards,
Brad

[poopdeckpappy]

You should have a set of these anyhow, this is a good excuse to get'em

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