DW735 Planer: Removing Screws

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Forum topic by jasoncarpentry posted 03-31-2013 12:54 PM 1615 views 0 times favorited 11 replies Add to Favorites Watch
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127 posts in 1698 days

03-31-2013 12:54 PM

(Heads up: This is a rant. I don’t think anyone can help me othrer than just sympathizing.)

We had a recent thread on how hard it is to change blades on the DW735 planer (I’d provide a link to it if I knew how). The consensus is that the bolts must have been installed by Arnold Schwarzenegger using a pneumatic driver, ‘cause there was no way I could remove them w/o using a bolt extravctor which, as you know, ruins the bolt heads.

OK, fast forward to yesterday, when I started to install my new Byrd Shelix Cutterhead. In addition to removing the blades, this requires the removal of a few Phillips-head bolts. Bring in Arnold again, ‘cause some of them came out easily (using lots of WD-40), while some just won’t budge. As soon as I relocate my bolt extractor, I’ll drill the heads out and try to remove them. The best case scenario will be the removal/ruination of these bolts.

One way or another, I’ll get the Byrd installed, but it aggravates me that Dewalt (and maybe other tool manufacturers as well) seem to put their tools together in such a way that there is NO FRIGGIN’ WAY to remove some of the bolts using standard methods. WHY??

-- Jim in Tennessee

11 replies so far

View JustJoe's profile


1554 posts in 1082 days

#1 posted 03-31-2013 01:29 PM

I’m working down my list of tools to buy and the new cutterhead is about 3 tools down – so if you could take a few pics along the way of what screws to expect trouble from it would be greatly appreciated.

There’s probably an automatic screwgun on the assembly line that someone has switched the setting from “snug” to “weld that sucker on there for good.”

-- This Ad Space For Sale! Your Ad Here! Reach a targeted audience! Affordable Rates, easy financing! Contact an ad represenative today at JustJoe's Advertising Consortium.

View redSLED's profile


790 posts in 936 days

#2 posted 03-31-2013 02:04 PM

Recent DeWalt DW735 planer blade screws rant:

Factory WAY-overtightened screws = poor quality control. Hey DeWalt wake up!

Someone send these thread URLs (, and the one just above to DeWalt corporate headquarters North American customer service demanding a written reply concerning resolution. And indicating how many LJ members there – might get their attention.

-- Perfection is the difference between too much and not enough.

View devann's profile


1915 posts in 1736 days

#3 posted 03-31-2013 04:38 PM

Jim, I was recently working on a garden tiller and come across the same problem. Using a screwdriver I could tell that I was going to damage the head and would have to resort to the screw extractor. From past experience I knew that the cordless drill/driver would also probably result in stripped screw heads. If you have a cordless impact try that. Make sure that you have the proper fitting tip. The impacts generally have 3xs the torque of the drill/driver and will loosen even the most stubborn fasteners without damaging the fastener. It worked for me.

-- Darrell, making more sawdust than I know what to do with

View Shawn Masterson's profile

Shawn Masterson

1270 posts in 992 days

#4 posted 03-31-2013 07:59 PM

try an impact driver. the old type. You put a bit in it and wack the end with a hammer.

like this

View woodbutcherbynight's profile


1443 posts in 1452 days

#5 posted 03-31-2013 09:57 PM

Shawn Masterson +1 I am with you, the old brute force method may not be pretty but it works. Often on Honda front wheels the brake rotor is attached with a set screw from the factory. Being different metal than the rotor and stressing with the heat they get stuck, impacting by pneumatic force works sometimes, most of the time, impact screwdriver and a hammer. They are fairy cheap at HF and having one around when you need it pays off. If you feel a burnign desire to own a high end one find a Snap On dealer, bring a credit card or a large wad of cash and have a few drinks to cushion the sticker shock. (Laughing)

-- Live to tell the stories, they sound better that way.

View verdesardog's profile


118 posts in 1655 days

#6 posted 03-31-2013 11:50 PM

You will love your new cutterhead when you get it installed! I don’t remember having trouble taking the old head out, but changing the blades on it did require using my makita impact driver with the proper torx bit….

-- .. heyoka ..

View teejk's profile


1215 posts in 1728 days

#7 posted 04-01-2013 12:20 AM

Shawn…I would be a little worried in using the old hand impact drivers. Those things require quite a severe hammer blow and I’d be afraid of wrecking the mounts. The battery impact drivers and the old air impacts (i.e. the tire changers) deliver little “bursts of hammer” as they try to spin the fastener out. I think the key is being able to keep downward pressure on the tool while it attempts the spin.

View LoydMoore's profile


100 posts in 1000 days

#8 posted 04-01-2013 12:33 AM

I have the same problem with my PC table saw. The front and back panels come off without a hitch but the side panels are there until I have to change belts. For now, I can do all of the maintance I needed but when belt changing time comes I am guessing I will have to drill the heads off and buy new screws.

Haven’t had any problems with the screws on my 735 planer but as I read the reviews prior to ourchasing mine there was a lot of discussion and it was reported that Dewalt had corrected the problem and I made sure mine was made after the date that was listed.

-- Loyd, San Angelo, TX

View ChefHDAN's profile


634 posts in 1893 days

#9 posted 08-18-2015 04:40 PM

I just finished getting my blades flipped, fortunately because of this community I was aware there would be issues with the allen head screws and proceeded cautiously following the advice given and was able get through the job without any major problems. For any of you with this task in your future, here are the steps I took to get the job done.

1) disassemble to expose cutter head etc.
2) soak each head with penetrating oil spray, (WD40 wouldn’t do it, waste of time), Total soak for me about 30 minutes for each.
3) with a punch and small ball peen hammer, give each bolt 5 sharp taps
4) DO NOT try to use the supplied tool to remove the bolts, use a quality 4mm allen wrench. Don’t get suckered in to trying the 5/32” imperial, I “almost” stripped one and then went searching for my metric set, 4mm fit perfect, and didn’t slip when fully seated in the head.
5) each bolt loosened without any swearing or real grunting, if it’s not loosening repeat #2 & #3
6) once loosened, remove the hold down bar & blade cleaning the oil from all and reinstall with the new edge/blade
7) snug each blade and then a 1/4 turn past snug puts plenty of torque on the bolt.

I have ordered the Tork kit off amazon, best price with free shipping for $20, Dewalt wants $22 & $11 for shipping

-- I've decided 1 mistake is really 2 opportunities to learn.. learn how to fix it... and learn how to not repeat it

View MrUnix's profile


2099 posts in 1243 days

#10 posted 08-18-2015 04:53 PM

OK, fast forward to yesterday, when I started to install my new Byrd Shelix Cutterhead. In addition to removing the blades, this requires the removal of a few Phillips-head bolts. Bring in Arnold again, cause some of them came out easily (using lots of WD-40), while some just won t budge. As soon as I relocate my bolt extractor, I ll drill the heads out and try to remove them. The best case scenario will be the removal/ruination of these bolts.

Stubborn screws are not exclusive to DeWalt. Penetrating oil, heat and torque all work well. If you can’t use (or don’t want to use) a handheld impact driver, this works as well or maybe even better:


-- Brad in FL - To be old and wise, you must first be young and stupid

View dschlic1's profile


243 posts in 1013 days

#11 posted 08-18-2015 07:16 PM

I would add to the procedure list above, clean out the socket in the screw head before trying to loosen the screw. I found that the indentation on my planer filled up slightly with dust and prevented the tool from fully entering. I took a utility knife and scratched out all around the depression and then blew out the loose debris. Pounded the driver into place and then used an impact wrench. The only screw I messed up on was one I tried before cleaning the depression.

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