Can't pull out damaged screws

I have a couple of screws on an exterior light that have been exposed to the elements for years. The light needs to be replaced so I wanted to unscrew the exterior plate. But the screw head is damaged. I tried using a phillips head but that didn't work. Based on advice on the web I tried using a flat head, but that just made matters worse. Any suggestions here? I don't have any tools other than the basic manual screwdrivers but I can go and grab something from HomeDepot if necessary. Please advice!

 

I use a abrasive cutoff wheel in a Dremel tool to cut a nice sharp slot for a flat blade screwdriver. Then get the largest sized flat blade screwdriver that will fit in the slot. Push VERY hard and turn.

If that doesn't work I use a drill bit and drill the head off of the screw. Sometimes I will use a grinder bit in a Dremel to grind the head of the screw off. Then when the screw heads are gone the cover can be removed. Spray the protruding screw bits with a penetrating oil like Liquid Wrench or WD-40 and let it sit for a while. Then grab the protruding screws with Vice Grip pliers clamped really hard and try to unscrew them.

 

Do you need to remove this to get to a bulb to change then replace this cover? If so then I would get a drill bit the size of the screw head and drill the head off the screw. Then after it is removed you can finish removing the screws with pliers or vice grips. If you don't need this part and will be replacing the whole thing then I would try breaking the area around the screw then after it is out of the way remove the screws with pliers or vice grips.

 

One of the work-arounds is to lay a rubber band over the screw, use the screw driver topress the rubber band into the screw head, and turn. Here's a video:
https://www.google.com/url?sa=t&sour...P19y3XhZFPpACS

 

An impact driver will also help break the screw loose, or break the screw.

 

Impact drier will probably just bust the fixture.

Your going to have to drill them out, and then re-tap to a slightly larger screw.

They are fully corroded in there and will not come out using any type of screw driver or rubber band!

Once you get them out use SS screws so they dont corrode again!

 

Get some duck-tape, cover the bottom 2/3 of the holes so liquid won't leak out. Soak them with penetrating oil or WD40. Wait a day. Repeat Try TIGHTENING them using 2 fingers on the screw driver- you should feel a "click" when the thread breaks loose.
If you don't feel the screws move, then repeat using lemon juice or cheap white vinegar- both are weak acids which will break though the rust. Try again the next day.

 

Rubber band didn't work. And the screw head has gotten worse. Will probably have to use a drill bit. (haven't tried that before and I'm not sure if have the right kind of drill bit that can be used on a metal screw).

 

I have never "busted" a fixture when using an impact driver. I have only broken the screw.

When drilling, use a drill bit for metal just a tad larger than the shank of the screw. (A little bit smaller than the head) All you are trying to do is drill off the head so you can remove the face of the fixture and gain access to the screw.

 

Personally, I would just drill the head off as per badeye.

 

Sorry for the dumb question, but should I use the metal drill in counterclockwise direction (outward) or should go I clockwise? Also, what do I do after drilling a hole through the screw - how do I pull it out next?
(yep...these are dumb questions...hence the Novice tag)

 

It's a small screw and should be easy to remove. I think I would try an easy out.

 

Drills only drill in clockwise direction.

Do this, drill out the head, get the cover off. carefully try the vise grip recommendations, even add some rust dissolver but typ that is wishful thinking, as the threads are rusted sold so nothing can penetrate.

Another thing you can try, heat up the housing, any minor expansion of the metal will help.

Easily try to remove but I'll bet the screw breaks off and you then will have to drill out the entire screw.

It's a pain but it can be done!

 

Left hand drill bits are readily available.

 

Any cordless drill drills in both forward and reverse. Your better corded ones will too. And as mentioned, you can buy left handed drill bits. Sometimes it's handy to drill in reverse and maybe back out what you are drilling. In this case, it doesn't matter either way. Once you drill the heads off the screws, the fixture will come off and then you can try to use a vise grips on anything that's left.