Foil repairWhat to do if screws are torn off?

Manuel Vogel

 · 09.01.2023

Foil repair: What to do if screws are torn off?Photo: Manuel Vogel
Torn screws are one of the biggest annoyances when foiling. In this workshop, we will show you how to remove the screw remnants from the thread and what you should look out for when repairing foils.

Most manufacturers of foils now use screws with sufficient dimensions to withstand the high forces that occur when foiling. Nevertheless, it happens time and again that screws break off. The reason for this is usually that screws shake loose unnoticed, e.g. at the connection between the mast and the plate. As a result, the screws bend and eventually break off.

The greatest danger here is that you lose parts of the foil. Therefore, check the screw connections regularly and tighten them if necessary!

Foil repair - how to remove torn screws:

If a screw is torn off, there is usually a part stuck in the thread. Unscrewing this is difficult, especially if the screw was bent and is very tight in the thread. However, with the right know-how and a few tools, you can quickly get your foil ready for the next session.

Common problem: The connection from the plate to the foil mast has shaken loose, the mast sits slightly askew in the mount (recognisable by the white abrasion on the mast)Common problem: The connection from the plate to the foil mast has shaken loose, the mast sits slightly askew in the mount (recognisable by the white abrasion on the mast)When the plate is removed, the problem becomes apparent: one screw has been torn off (right) and is firmly stuck in the threadWhen the plate is removed, the problem becomes apparent: one screw has been torn off (right) and is firmly stuck in the thread

The solution:

You will need the following for the repair:

  • Vice
  • Drill with metal drill bits
  • Pliers
  • Screw extractor - these are available as a set from DIY stores. Cost: 10-25 euros

And this is how the foil repair works:

Fix the film mast in the vice, you won't need the screw extractors until later...Fix the film mast in the vice, you won't need the screw extractors until later...Now carefully drill a channel into the torn-off screw. Use a metal drill bit that is about half as thick as the screw itself and make sure to drill in the centre and vertically so as not to damage the thread. Drill about 10-20 millimetres deep...Now carefully drill a channel into the torn-off screw. Use a metal drill bit that is about half as thick as the screw itself and make sure to drill in the centre and vertically so as not to damage the thread. Drill about 10-20 millimetres deep......and then screw in the appropriate screw extractor. Note: This has a left-hand thread and gets thicker towards the top. If you continue to screw in the screw extractor with the pliers, the screw will start to unscrew at some point....and then screw in the appropriate screw extractor. Note: This has a left-hand thread and gets thicker towards the top. If you continue to screw in the screw extractor with the pliers, the screw will start to unscrew at some point.
Done - the screw is outDone - the screw is outAlways check the other screws as well. If they are slightly bent, replace them immediately. Torx screws (right) are generally more suitable than those with a hexagon socket because the heads do not wear out so quickly.Always check the other screws as well. If they are slightly bent, replace them immediately. Torx screws (right) are generally more suitable than those with a hexagon socket because the heads do not wear out so quickly.

There are also always problems with foils at the connection between the mast and the fuselage. For this case you will find HERE another workshop!

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