Aluminum screws, while lightweight, can sometimes strip easily, especially if over-tightened or used with the wrong tools. Stripped screws can be a significant hurdle during repairs or upgrades. This tutorial will offer some ideas and guide you through the steps to remove stripped aluminum screws from your FPV drone efficiently and safely.
Table of Contents
DO NOT DO THIS
Never use aluminum bolts to mount your motors! I learned this the hard way. It’s very easy to strip aluminum screws, especially when we typically apply threadlocker to them. You are likely to never get those screws off the motors again unless you cut them off completely with heavy tools.
What metal screws shoudl you use? Check out our guide: https://oscarliang.com/screws/
Step-by-Step Guide
Inspect the stripped screw to determine the extent of the damage. This will help you decide the best method for removal.
Dremel Tool Method
If screw head is completely stripped this might be useful.
- Step 1: Use a Dremel tool with a cutting disc to cut a straight slot into the screw head.
- Step 2: Insert a flathead screwdriver into the slot.
- Step 3: Apply firm pressure and turn the screwdriver counterclockwise to remove the screw.
If you don’t have a dremel tool, use other tools to make a nice straight cut big enough for the flathead screwdriver.
Needle-Nose Pliers Method
- Step 1: If the screw head is slightly protruding, grip the screw head with needle-nose pliers.
- Step 2: Apply firm pressure and twist the pliers counterclockwise to unscrew.
Rotating Motor
If only one of the screws is stripped, you can try removing the other screws, desolder the motor from the ESC first. Then instead of trying to rotate the screw with your screwdriver, hold the stripped screw with you thumb and rotate the motor instead of the screw this time.
Torx Bit Method
- Step 1: Choose the correct size torx bit
- Step 2: Hammer the bit into the stripped screw head and apply firm, steady pressure.
- Step 3: Slowly rotate the drill to allow the extractor to grip and remove the screw.
Rubber Band Method
- Step 1: Place a wide rubber band over the stripped screw head.
- Step 2: Insert the screwdriver into the rubber band and press down firmly.
- Step 3: Slowly turn the screwdriver. The rubber band can provide extra grip, allowing the screwdriver to turn the stripped screw.
Superglue Method (for last resort)
- Step 1: Apply a small amount of superglue to the top of the stripped screw.
- Step 2: Place the screwdriver into the glue and hold it in place until the glue sets.
- Step 3: Once the glue is set, carefully turn the screwdriver counterclockwise to remove the screw.
Drilling Off Screw Head
If nothing works, try completely drilling off the head of the screw with a drill bit that matches the thread diameter. When the head of the screw comes off, you can remove the motor and take the threaded portion out with a pair of pliers. (heat it up fairly well to help loosen the thread lock)
Be sure to bag the motor up and leave only a small gap for the screw head, metal filings in motors is a real pain.
Additional Tips
- WD-40: If the screw is stuck due to corrosion or debris, apply a small amount of penetrating oil like WD-40 to the screw and let it sit for a few minutes before attempting removal.
- Heat Source: Gently heating the area around the screw can sometimes help expand the metal slightly, making it easier to remove the screw. Especially helpful with threadlocker.
Conclusion
Removing stripped aluminum screws from an FPV drone can be challenging, but with the right tools and techniques, it is manageable. Always use the appropriate tools and take care not to apply excessive force, which can cause further damage. Regular maintenance and careful handling of screws can prevent them from stripping in the first place. If you encounter a stubborn screw, patience and the right method will ensure successful removal. Happy flying!
Edit History
- July 2016 – tutorial created
- Jan 2024 – updated
7 comments
You can also use a metal file to shave both sides of the screw head, making two parallel flat surfaces that you can grab and twist with some pliers.
#6 worked for me! Thanks.
Awesome article Oscar, using idea #2 I was successfully able to remove the stripped out bell retaining nuts from some BrotherHobby 2206 Returner motors which were desperately in need of a cleaning after I got ferrous black-beach sand (a.k.a ironsand) into them! Thank you, I would have never thought about this!
thank for the many ideas on this post! I’m a drone builder and cane across this issue today. Not the fist time but the most critical time was at hand. After purchasing a few tools that had hopes or working didn’t. I wasn’t giving up.
I cane across this page, read all ideas. Number 1 stuck out like a beautiful blonde. I read the rest and tried idea 6 first. When that failed I pulled out the Dermel and DONE! This is the internet at it’s finest! Thank you once again for the post!!
I took the hex wrench and some two part epoxy and epoxied the wrench head into the stripped screw head. Boom!
Never use aluminium screws & nuts! Use stainless steel. Weight what you can save with aluminium is insignificant…
Actually using aluminium screws can save a significant amount of weight.
Even if the difference is in the ones or low tens of grams, any saving will give you better flight performance.
On quads, every gram counts!