I have a multi-family and replace Diverter Valves regularly. (Not the same valve over and over again, mind you :) Last's night episode has me snapping the head off the handle screw. I completed the job but now the tenant has a handle that can't be secured. I would hate to replace the spindle. It is 15+ years old and not an issue at the moment. Any words of wisdom folks?

Thanks in advance!
corms_99

Drill the broken screw out and replace it. Or if there is enough left to grab with needle nosed pliers? Or use a screw extractor,

http://ecx.images-amazon.com/images/I/41VIV5rdMlL._AA160_.jpg

https://www.youtube.com/watch?v=Z_6RUa0fH4U

You may have to rethread, (tap) out the screw hole.

http://www.micromark.com/RS/SR/Product/82322T_T.jpg

Thanks for the reply Talaniman... The screw head snapped off and left very little of the screw left to grab with needle nose. (I tried with a set of Electrician's Lineman Pliers... whatis left of the screw is simply too soft to dislodge the threads from the spindle)I may have to drill the screw out.. the question is will the drill allow me to collapse the seated threads of the screw once I have enough of the screwbody gone... without damaging the threads in the spindle, of course. (Always a catch)I guess I just may have to try it...

See the rest of my response about tapping the threads out. You may not need to if the extractors work. You don't have to drill through the whole screw, just enough for the extractor to bite. Changing the spindle is another option, probably the easiest unless you have the tools you need already.

I've never had good luck trying to use an extractor for a screw that small.
My suggestion would be to put the spindle in a vice. Using a hacksaw cut a slot about 1/8 deep through the screw and the spindle. Then using a small flat blade screwdriver try to remove the screw.
If that doesn't work, the slot will help guide the drill bit to the center to drill out the screw. Drill with a 1/16 bit and then enlarge the hole and tap for a larger screw.

Thanks for the suggestions guys... the hacksaw approach is ingenious. I'll be trying again this weekend. (From less destructive to most destructive approaches!! ) I'll let you all know how it goes.

Thanks again!
corms_99

Corms,
I like the hacksaw / screwdriver approach; I have used it with great success. I would also heat the end of the spindle with a torch, and cool it quickly with an ice cube or some snow - this expansion and contraction will help dislodge the screw...

Another approach, I think you would call this one less destructive. Plus it is done "on site".

The problem with drilling the broken screw is finding the center, or some where close to the center.
Even if you find the center, the screw is broken and the end is rough. That will kick the bit off center when you start to drill. Plus, if you are going to use an extractor, the hole has to be large enough to get the extractor started.

The suggestion is to first smooth out the end of the broken screw.

You do this using the handle as a guide and a drill bit the same size as the screw hole in the handle. Put the handle on the spindle, then pull it back about 1/8". This should allow the drill bit to pass through the handle beyond its beveled end. Use the "peck drilling" method of drilling. Start the drill with no pressure, apply light pressure for a few seconds, then pull back, then apply pressure again. This clears any chips, keeps heat down and keeps you on center. Drill only enough to smooth out the end of the broken screw and create a slight bevel toward the center of the screw. Won't hurt anything if you bevel the end of the spindle slightly.

After smoothing the end of the screw use a self centering bit to drill a small hole in the screw. Again using the "peck drilling " method. Drill about 1/4 to 3/8".

Remove the handle from the spindle. Place a small piece of masking tape or duct tape on the end of the spindle. Press it down to ensure that it is firmly attached to the end of the spindle. Do not wrap it around the spindle.

Use a small finishing nail (same size as the hole you drilled) and pierce the masking tape. After piercing the tape, again press the tape down to ensure that it is firmly attached.

Coat the end of the finishing nail with Super Glue and insert it into the hole in the screw. Immediately remove the masking tape. It's purpose was to prevent glue from getting between the screw threads and the spindle. If there is any possibility you got glue on the screw threads remove immediately.

After letting glue dry, use pliers to turn the finishing nail and screw. Nothing to loose here except your time and effort.

Of course, before you start, you should make sure that the drill bit and the finishing nail are the same size.

Are you done yet?

Handle is attached to the stem. Stem is $20.00. I would buy new stem, new handle, install it in 10 minutes and job is done.

We never take chances on rental properties. Please, keep in mind that this is rental and renters will break everything in no time. So if you try to somehow "fix" it with glue, etc, chances are you will be doing it right again in few weeks.

Milo

Milo
We are not trying to fix any thing with glue. We are just trying to get the broken screw out. Sometimes it is just the challenge.

Funny how something as "basic" as a broken screw can generate awesome conversation. Thanks guys... all suggestions are worth are 5 stars.

I did get it fixed... by...

1. Trying to grab the remaining screw with a set of pliers. The screw material was simply too soft.

2. Then we take out the drill. I did have a bugger of a time getting it centered. As some have stated I was off-center by quite a bit. I solved this by simply taking my time and applying "side pressure" to the drill bit to continue to take material off the "high side". Once I had enough screw removed, I was able to take pliers and continue to collapse the threads and continue to remove with the drill.

3. Then believe it or not I was able to tap the material (Probably still some of the screw) with the same 8-32 size it originally was.

4. Once it was gently tapped, a Home Depot replacement screw went in nicely and help firmly.

Job done!!

Thanks for all the suggestions... though I didn't use some of them I'll never forget them. (Hack saw trick... brilliant... )

Congratulations

You got 'er done, nice job!