Reply by RogerBean

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Posted on Broken brass screws. Aaaargghhh!!!!!!!

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1605 posts in 3190 days

#1 posted 07-27-2010 12:48 AM

I have lived in fear of this very situation for a long time, but have not had to deal with it. My inclination is as follows: If you have a Dremel or trim router, take a 1/8” straight bit and route a slot up to the broken screw without actually touching it (or maybe drill on both sides) so you can dig the broken parts out. Some sort of jig to get a clean cut would be preferable to freehanding it. The small router bit would then be able to cut a clean slot so you could make and glue in a snug-fitting plug. If you’re careful, you can make a nice clean job of it with everything covered by the hinge. If the same wood, it should be invisible. If it’s a quadrant hinge you have a bit more room to work and fit the plug.

Sounds like your drill may be a little too small. I also counterbore the top a little rather than try to force the unthreaded shank part into the wood. A little parafin or other wax on the screw also helps it go in easier. Some guys use steel screws to cut the initial bore and then install the brass ones.

I will be watching this post for any better ideas. This will probably happen to me tomorrow!

Good luck,

-- "Everybody makes mistakes. A craftsman always fixes them." (Monty Kennedy, "The Checkering and Carving of Gunstocks", 1952)

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