Favorite technique for removing rusted screws??

Had a Cessna 172 come into Emergency Aircraft Repair at Oshkosh with a
damaged spinner. The lady pilot want it removed so pieces didn't fly off
during the flight back home.

Unfortunately, the spinner hadn't been removed in many years. The Screws
were rusted tight. Used all of the techniques that have been listed and
failed to remove a single screw. It looked hopeless as all the slots got
rounded out.

I got out a sharp cold chisel and after getting a good bite on the side of
the screw head, angled the chisel to rotate the screw. Took about a minute a
screw to get them started to have them protrude enough to grab with vice
grips and spin them the rest of the way out.

Lady pilot was a little perturbed when I said that the spinner should have
been removed at every annual time by the mechanic so as to check the prop
bolts. Her response was..."I'll tell that to my husband, the IA.! LOL

--
Cy Galley - Chair,
AirVenture Emergency Aircraft Repair
A 45 Year Service Project of Chapter 75
EAA Safety Programs Editor - TC
EAA Sport Pilot

" wrote in message
ps.com...
After you do all these things to the head, you will have enough torque
to twist the head off!
Then you will need the extractors.

I've found you can use the dremel tool to make a square like head on
the screw then take it
out with a vice grip.

Bill Hale


wrote:
I have found these power extractors available at Sears to work very
well.

http://www.sears.com/sr/javasr/produ...TOOL&ihtoken=1

(copy and paste the address if it is too long)

I had to use them on a 6-32 countersunk screw in an inspection plate
under the leading egde. They have a carbide drill on one end (left
handed), with the proper size fluted extractor on the other end. For
small screws, the drill set on reverse usually does it. In fact, in
some instances, the left hand drill backs the screw out without using
the extractor (you do need a reversing drill).
Also, the advice to use replaceable tips in the screwdriver is a
good one. Even the best screwdriver will eventually get worn and be
susceptible "cam out". There are tips that have small spikes in the
groves that really grip well, especially when you also use a good paste
or compound too increase friction. They are much cheaper than having to
replace the whole screwdriver. A good oil penetrant like Aerokroil or
Mousemilk is good too. I've never tried the penetrant you used. Does it
work well?

Regards,
Bud

Michael Horowitz wrote:
I'm disassembling an alerion and am running into a lot of small steel
round headed screws that attach aluminum sheet to steel tube.

Before attempting to remove these screws, I apply PB Blaster and let
them sit 24hrs. then I ensure the screwdriver slot is clean. Then
sometimes the screw backs out nicely; other times the screwdriver
slips out, beginning the process of rounding the head.

Does anyone have a series of steps they'd care to share on removing
rusted screws? - Mike