DRILL-OUT MICRO EXTRACTORS

1. Obtain a variable speed reversible electric or battery powered drill and set it for reverse (counter clockwise).
2. Measure the diameter of the broken screw to determine the size Drill-Out® Micro required. For example, if the broken screw measures .184 or 5mm in diameter, use M5 or #10 marked Drill-Out® Micro. We recommend a 1/4 or 3/8 variable speed electric or battery powered drill set for reversible mode. Impact or high horsepower drills may cause damage to the Drill-Out® Micro.
3. Attach the round end securely into the drill chuck. See Figure 1.
4. Place the top of the Drill-Out® Micro on the center of the broken screw and begin drilling at very low speed. With the hole started, stop and observe, making absolutely certain that you are at the center of the broken screw. If you are not centered, simply angle the Drill-Out® Micro toward the center of the broken screw and drill until the point of the drilled hole is on center.

    

   The most important step in extracting a broken screw is to drill the hole on center and straight.

5. With the hole started on center; hold the drill parallel to the axis of the broken screw and continue drilling at very slow speed, approximately 75 to 100 RPM. Do not drill at medium or high speed. Stop every 1/16" or 2mm in depth to clean out the chips and add cutting oil. Verify each time that you are drilling on center and straight.
6. Stop drilling when you reach the major diameter of the tool body.
7. Clean out chips from the hole and use penetrating oil to help loosen the broken screw.
8. Remove the Drill-Out® Micro from the drill chuck and reattach the tool at the opposite end which has the hex portion.
9. Hold the electrical or battery powered drill firmly with both hands, set on reverse.
10. Place the tool into the drilled hole. Apply pressure to wedge the Drill-Out® Micro in the hole. At that moment, slightly touch the trigger to start the drill while applying pressure on the Drill-Out® Micro See figure 2. The tool will engage and remove the broken screw quickly and effectively. Use only very slow speed when extracting, approximately 50 to 75 RPM.
11. If the drill stalls during extraction, hand removal is possible. Leave the Drill-Out® Micro lodged into the screw and remove the tool from the drill.

     

    Look to see if you have drilled exactly on center. If so, use a wrench on the hex portion of the tool and turn counter clockwise to remove the broken screw. Do not use excessive force; damage to the tool may occur. If excessive force is used, the tool will not break inside the broken screw; it is designed to break at its weakest joint, the undercut at the center of the body. At no time will you be left with a worse situation that when you started.

     

    If you get a lot of resistance when using a wrench, you may have drilled off center and the Drill-Out® Micro tool is biting on the casting or you may be in an impossible situation. if this situation arises, remove the Drill-Out® Micro tool by turning clockwise. You may have to drill and tap new threads or install a threaded insert.

12. To remove the Drill-Out® Micro from the broken screw, firmly tighten the broken screw in a vise. Using an adjustable wrench on the hex portion of the tool, just turn clockwise. Your Drill-Out® Micro is ready to be used again.

HELPFUL HINTS

• Center punch before drilling to shock the screw.
• Penetrating oil or heat is effective on rusted or chemically bonded screws.