Tube Extractors are the Best Option
Sawtooth edges make these small tools very handy to have around the shop. Use a drill press, if possible, to bore a clean hole around the screw. Or, a hand-held drill with a guide block works fine for screws located outside of the reach of a drill press. Once the screw is out, patch the hole with a length of dowel or a matching plug.
– For screw sizes #4 – #8, use a 1/4″ tube
– For screw sizes #4 – #10, use a 5/16″ tube
– For screw sizes #10 – #12, use a 3/8″ tube
Tips to Avoid Breaking Screws
– Use a better quality screw.
– Drill properly sized pilot holes, which are different for hardwood and softwood (see chart at below).
– Lubricate the screw with wax or paraffin. Grease or oil may leach into the wood causing finish problems.
– Always clamp the workpiece to your bench or in a vise to hold the piece securely.
– For brass screws, first install a steel screw of equal size to thread the hole, then replace that screw with the brass screw.