Mrs. Obscure requesting help. Door bolt / screw

[ObscureMachine]

Hi! This is Mrs. OscsureMachine. I am rebuilding the doors (FUN!) as a birthday present. There's this one phillip's head screw at the top of the door. I think it's under and between the window frame and the vent window. You can see it in the picture. I stripped it, the tried numerous methods and then decided to drill it out. Now this is where I am and have no idea how to proceed. Have I messed this up really bad? I'm trying to surprise him.

Would you guys be willing to help me out? What do I do next? What did this screw/ bolt really go to? If you have pictures I would be forever grateful!

Thank you in advance,
Michele

 

[Slowleak]

That screw goes into the frame that holds the vent window. It’s a 1/4-20 screw and I think it’s about 1 3/4 or 2 inches long.

 

[tatersalad]

What he said

 

[Skiddy]

and a very cool birthday present

 

[DirtDonk]

Totally! Now you just have to ask yourself... Is it worth it!
Of course the answer is yes. But as you sit there pulling your hair out (instead of him doing it) the thought must cross your mind.
So I just said it out loud.;D

Sorry I'm no help specifically on this. Some screws are easy to drill out, but that's an awkward one it looks like. Lack of support on the back for one thing, making it move around on you. Or is the assembly still solid in there so you can get the drill on it?

Have you at least sprayed the daylights out of it with some penetrating lube? Not sure what's in the garage, but AeroKroil, Liquid Wrench (old school and not as effective, but still works), or some other type. WD-40 even if that's all you've got, but it's more of a light lube than a penetrant. But it still can get into some of the rust that is no doubt holding that old screw in.

How long do you have that you can keep this a secret? I wonder if that part will come out now that the head is broken off and you can work on it outside the door panel.
Being the weekend, he's probably going to sign on the computer and is going to find out anyway. So maybe a joint-venture at that point?

Good luck. I'm sure someone here has run into the same problem with the same screw and will have some insight.

Paul

 

[Cortez]

Is there enough left that you could weld a nut to it? I’ve never done that but many here have recommended that method. I have had luck with screw extractors also, but you need to drill a hole in the middle of the screw and that one isn’t very thick in diameter. As stated spray the back side with penetrating oil for a few days if you haven’t already done it.

 

[bronkenn]

First of all, welcome. Was wondering how far you were going with the door rebuild? Complete teardown then that screw has to come out to remove vent window. Now that your this far you are going to have to drill it out. That is a fairly small screw so it shouldn't be too hard to do. Start with a 1/8th inch drill (sharp) and center punch to get the hole as centered as possible. Make sure to keep the drill good and straight as you drill. Go as deep as the screw is. Be patient and then move up to a 3/16 drill. Then you can go to the size for tapping. I think that is a 1/4 inch screw (thanks slowleak) so a 13/64 drill should do it. Again take your time and it will be a good experience. By the way I think Jim will be tickled pink knowing what you tried to do this regardless if it doesn't come out the way you wanted. Good Luck with it, Ken

 

[Slowleak]

The screw is 1/4-20 x 1 3/4

 

[bronkenn]

The screw is 1/4-20 x 1 3/4

Thanks, My mistake, that would need a 13/64th drill bit instead of 17/64th. (corrected it in post) Ken

 

[suckerpunched]

I don't any way to drill that screw, it is too long. you will never stay centered and you will have to get quite aways into it before yo get to the where it is threaded into the window frame. I don't have any doors that apart that I can look inside of anymore. but is there any way to get ahold of it from inside the door with vice-grips or double nut the tail and turn it. If you could back it out a little and get it to slightly stick through the door, you could then weld a nut to it.

 

[suckerpunched]

If you can't get at it from the back side, maybe you could grind a nut down to a cone shape that would fit down into that pocket and get close enough to weld it to the end of the screw without welding it to or burning into the door.

 

[ObscureMachine]

YAY!!! I GOT IT! The bolt was rusted to the plate inside the door and wouldn't budge, plus I'm really little so that made it harder. I found a hacksaw blade and cut and cut and cut from the top and eventually it broke. Then the vent window came right out! I have both doors completely stripped! Now I know why Jim loves getting on here! Thanks for all your help. I'll probably be back soon for more.

Sincerely,
Mrs. Obscure Machine

 

[BronCowie]

Have I messed this up really bad? I'm trying to surprise him...

Thank you in advance,
Michele

Congrats Michelle. Working on old vehicles do present challenges like this. I'm glad you got it. I'm curious though, how can this be a surprise if you're posting this here, especially under Jim's user name? ?:? ;D

 

[DirtDonk]

I think he must be on a "time out" and not allowed near the computer until certain parameters have been met.;D

Mebee the rest of the family is keeping him busy?
Or a "sorry honey, the internet is down for the weekend" or "overloaded due to late Mother's Day gift searches" kind of story.

Paul

 

[suckerpunched]

great news, good job. thats the way things often seem to go. (not as planned) they can be a pain in the butt, just have to figure them out.

 

[No Hay]

I think he must be on a "time out" and not allowed near the computer until certain parameters have been met.;D

Mebee the rest of the family is keeping him busy?
Or a "sorry honey, the internet is down for the weekend" or "overloaded due to late Mother's Day gift searches" kind of story.

Paul

Hopefully the crazy neighbor didn't get him!

I'm back in Salem till July or so getting Mary's house prepped for sale if a work party is ever planned or needed.
Kevin

 

[ObscureMachine]

Congrats Michelle. Working on old vehicles do present challenges like this. I'm glad you got it. I'm curious though, how can this be a surprise if you're posting this here, especially under Jim's user name? ?:? ;D

Well Mark, she did it while I was working on another project and then went out of town. She's a sneaky little thing! I walked in the front door and there were two stripped doors in our dining room! I hope she decides to surprise me with a new suspension!;D ;D ;D