How to remove screws deep in a mailbox that has a stripped head

Question

I thought replacing this mailbox would be easy... four bolts out and a new mailbox (identical to the old which has exterior issues) in.

But then I noticed the four bolts were actually Phillips head screws there were in there very tight. Using a stubby screwdriver, I was barely able to turn 3 of the 4, but the back left one in the image below stripped on my. I tried loosing these up with WD-40, but it didn't do anything.

It takes most of my arm to reach those back screws and I can't get enough downward pressure to hold the Phillips head screw in while also turning. I also tried a ratchet with a screwdriver bit, but there wasn't much room to ratchet and of course with the screwhead starting to strip the bit wouldn't stay in.

Assuming I get these out, I will try to find similar threaded bots, so a ratchet wrench can be used, but how do I get that back left screw out without harming the wood below the mailbox that it is screwed into?

Photo: https://i.imgur.com/ttKqjzz.jpeg

Answer 1

Probably need to "think outside the box" a bit.

Will the existing mailbox be disposed after it is removed? Then don't worry about removing it delicately. Pick up a claw hammer, tin snips, a reciprocating saw or jig saw or hack saw, or similar tools and smash and cut a hole through the top of the mailbox. You can create good access to the stuck screw and then apply your full strength with full-size tools to solve the problem.

If the mailbox must be removed without damage, try locking pliers on the head of the screw. They're not likely to hold well enough to turn it but it's worth a shot.

The head of the screw could be ground away with a small rotary tool (aka "Dremel"). After the mailbox is removed there'll be a stub of screw remaining. You may be able to remove that with locking pliers, or you may be able to simply grind it down further and abandon the screw in place. The fasteners for the new mailbox can probably go in different locations after all.

Answer 2

After removing other 3 screws, try twisting the whole mailbox counterclockwise while pulling up - it might loosen the screw.

You can also use the old fashion method:

• Take a blade from metal saw, wrap it in cloth and use the blade alone to cut a slot in the screw. Wide cutting blade is preferred so it doesn't flex too much.
• Use flathead screwdriver to unscrew the screw.

Note: You can also buy a dedicated handle for using the blade alone. Useful in tight spaces. And much more convenient than wrapping it in cloth.

Answer 3

Using a cutoff disk in a Dremel (or similar rotary) tool you could cut a slot for a flathead screw driver, or cut off two of the rounded sides of the head to make grabbing it with a wrench (if you're naturally gifted at cutting parallel in an awkward position) or locking pliers (for the rest of us) more practical.

If you are not refurbishing the mailbox the suggestion already made to cut it open could help.

I find this an unusual (and inferior) mounting method. All the standard mailboxes of this general shape I've met have holes through the sides, below the bottom of the box, which you can put screws or lag bolts through with good, easy access, into the side edges of the board that fits into the recessed bottom.

Answer 4

At this point, I'd be thinking about grinding the head of the screw away and then using some vice grips to remove the screw.

Answer 5

Does the mailbox have a lip over the wood it's screwed into? If not, you can try taking a metal hacksaw blade off of the saw (maybe hold with vicegrips), slip between the mailbox and the base, and saw through the screw.

Answer 6

You could try using a 90° drill attachment in an impact driver. I've done this quite a few times getting screws out that otherwise would have needed to be cut off with a grinder.

To tackle this you might need an extension to reach the back of the mailbox.

Image credit: Amazon.

Answer 7

Get a left-hand drill that fits the stripped-out socket. Take it easy with a power drill. You will feel when it catches. I have done this many times at work.