Join Date: Mar 2005
Location: Evanston, IL, USA
Need advice on frame fix...
One of the screws attaching the plastic side panel to the frame snapped off when removing the skin the other day. It was the one down low that goes directly into the aluminum frame. So even though some of the screw was sticking out, vice-grips were unable to get the thing dislodged. For whatever reason it was in there to stay. Tried anyway (my only choice really) and as predicted, the rest of the screw snapped off. So now my next choice is to drill it out. I did, put in a screw extractor, and THAT snapped off in the hole. So now I have a screw with an extractor stuck inside of it, both pretty much flush with the hole in the frame. I eventually drilled it all out, but that made a mess of the original hole in the frame. I really don't think I had other good options, so I'm not so upset about it, it's just the way it went.
So now I've got this ugly hole in the frame and need to retro fit a new screw somehow to hold down the skin at that point. One decent option might be to drill the hole out a bit bigger and insert one of those plugs that are made for such problems and which have threads inside them to receive a bolt (screw). The one I have on hand is made of brass, so would have to be dealt with delicately as I remove / refit the plastic in the future. The only other good option I can think of is to have someone weld a new piece of aluminum in place of the old, but I'm afraid to go down that path without trying some other workable solutions.
Before I drill this out to a larger hole, I thought I would ask you all what you thought of my choices here.
Thanks for any advice...
...enter something catchy here....