Windshield Repair Forum

The broken tip needs to be removed so that the repair can be completed properly. If it is sticking up above the surface of the glass, you may be able to remove it with a pair of small needle nose pliers or tweezers. Try twisting the bur counter clockwise as you are pulling it out. Some say you can use a magnet but I have never seen that method yield much success. If you are unable to get a grip on the broken tip, you will have to drill into the glass right next to it.

The most common reason for a bur breaking is because you drilled all the way through the first layer of glass and did not "wobble" your drill as you drilled. This is especially easy to do with a tapered bur. Be sure that when you drill the second hole, you wobble the drill and stop short of drilling all the way through the first layer of glass.

Once you have successfully drilled your second hole, use your scribe or pick tool to loosen the bur tip and work it up until you can grab it with the pliers or tweezers.

Now you have two drill holes to fill so cosmetically the repair will not look as professional as it could, but that is generally the only way to solve the problem.

Most busy windshield repair technicians have this problem once but now that you know the problem, it is unlikely to happen again. Good Luck!

Brent Deines
Delta Kits, Inc.

if you can't get it out and it broke under the top edge of the glass just fill and cure as normal with that much drilling needed the repair will look ugly anyway,
maybe thats what I see when I view others atemps and it looks like a brass filling in the middle of the repair, since no one eles has ever seen this but me. I've asked this question before and no one has seen repairs finished with little brass rods.

Delta's advice is right on the money. btw, I have redone old repairs and removed the tip of a bit a couple times... don't leave it there and make me remove it.

sprinter 1,I saw one of those brass fillings about 2 weeks ago.It almost looked as though it had been tapped in with super glue all around it.Strange Andrew

good someone eles has seen what I've talked about.

Maybe it's like a gold filling. Was it on a Cadillac? Could be worth a buck!

I leave them in and no one even notices. It just looks like a dark drill hole ... as long as you do the repair correctly it is not noticable and it shouldn't affect the strength of the repair at all.

I was glad to see Melee say to leave them in if they are below the surface. Attempting to remove them can really make a big mess if you arent careful. I have been fortunate. So far only a few tips have broken off. If the broken end protrudes above the surface of the glass, it should be removed. Usually it can be pulled out with a good pair of needle nose plyers. Occasionally, you might have to drill next to the broken piece just enough to give it 'wiggle room'. People dont usually look at their windshield from any closer than 2 to 3 feet, and from that distance, they would have to really be looking hard to even see the repair site, let alone if there is a broken tip in it. Certainly, if it can be easily removed without doing further damage, do so. Otherwise, just leave it in there.