Broken Screw Repair - Router Forums
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post #1 of 15 (permalink) Old 01-31-2015, 01:01 PM Thread Starter
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Default Broken Screw Repair

Dang it! I broke a screw!

Actually, this happen last year but I thought I would share how I resolved the issue.

I was building cabinets using hard maple. Even though I had predrilled a pilot hole in the door frame, the screw broke when I was screwing it in. Either the pilot hole was too small or the screw was too big. The idea of having to make a new door made me sick at my stomach.

After taking a break and thinking about my dilemma, I devised a plan to repair the broken screw. Note that this may or may not work in other situations, but it worked perfectly for me in this instance. Note: The screw broke flush with the wood. There wasn't anything that I could grip with pliers.

Step 1 - Remove the broken part of the screw

After removing the other screw and the hinge, I used a plug cutter to cut around the area containing the broken screw threads. Using a hand held drill, that was actually easy to do. And wouldn't you know it, I broke a second one while removing the hinges! Now that I think about it, maybe the cordless drill had too much torque and simply snapped it off.

Step 2 - Plug the hole

Using the next larger size plug cutter, I cut a few plugs from the same wood the doors were built from (hard maple). After that, it was a simple matter of gluing the plug into the hole(s).

Step 3 - Finish the repair

Once the glue was dry, I taped off the surrounding area and sanded the plug flush with the frame.

Step 4 - Reinstall door hinge

I used a slightly larger pilot drill bit and hand screwed the screws into the hinge. Not surprisingly, all went well. There is no evidence of any repair because the hinge covers the repaired area.

Hope you find this info useful. File it for future reference. You may need it some day.
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Last edited by MT Stringer; 01-31-2015 at 01:03 PM.
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post #2 of 15 (permalink) Old 01-31-2015, 06:25 PM
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post #3 of 15 (permalink) Old 01-31-2015, 08:48 PM
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post #4 of 15 (permalink) Old 01-31-2015, 08:58 PM
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Mike sometimes its the screw, quite often even with square head screws if the predrilled hole is too small the bit tends to torque out of the screw head with little encouragement. Or I've had a few screws twist out of straight (warp). With maple and oak I adopted the sacrificial pre-screw. Screw down, back out, screw down deeper then back out. I wreck a lot of sacrificial screws but I always have something to grab with the vise grip.

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post #5 of 15 (permalink) Old 02-01-2015, 12:31 AM
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I usually scrape a candle or piece of paraffin wax over the threads before driving them into hardwood or old D. Fir. You won't believe the difference.
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post #6 of 15 (permalink) Old 02-01-2015, 12:51 AM
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Good save, Mike...

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post #7 of 15 (permalink) Old 02-01-2015, 01:34 AM
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I buy the hinges with dowel no screwing,drill 3 holes hammer in the first time
Compact 33 Face Frame Hinge 110 Degree/Dowel (#33.3630) by Blum | Shop & Save at

Last edited by Semipro; 02-01-2015 at 03:30 AM.
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post #8 of 15 (permalink) Old 02-01-2015, 07:55 AM
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Good save Mike. I always keep a little bees wax or toilet bowl wax around whenever I am using any small screws that could possibly break off and be a problem. Small hinge screws and the like I run in by hand. Who knows where the screws come from and what quality they are.

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post #9 of 15 (permalink) Old 02-01-2015, 08:58 AM
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Mike........Nice save, and as always, nice pictures. And good ideas from everyone. A longer sacrificial screw and wax have become part of my routine. Jim

It seems I never finish what I
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post #10 of 15 (permalink) Old 02-01-2015, 09:24 AM
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I use plain Ivory bar soap for screw lube - slippery but not sticky.
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