Headlight Cover Broken Screw Removal
Thread Starter
Melting Slicks
Joined: Dec 2000
Posts: 3,363
Likes: 303
From: Lansdale 19446 PA
2024 C3 of the Year Finalist- Unmodified
St. Jude Donor '10-'11, '15, '19
Headlight Cover Broken Screw Removal
I searched through the C3 section but came up with no solution. When I gently removed the headlight bezels, a screw snapped of of each cover. A couple also broke off on my wiper door.
Is there any tricks to safely remove the broken screws without damaging the parts? I was thinking of making some sort of jig that would keep the drill bit straight & not move off to the softer metal.
Any thoughts, tips or tricks would be appreciated.
TIA,
John
Is there any tricks to safely remove the broken screws without damaging the parts? I was thinking of making some sort of jig that would keep the drill bit straight & not move off to the softer metal.
Any thoughts, tips or tricks would be appreciated.
TIA,
John
Team Owner
Joined: Jan 2006
Posts: 37,637
Likes: 3,118
From: Crossville TN
If there is any of the screw shank sticking out of the cover hole, you might be able to get a vise-grip on it and back it out. If it snapped off flush or below the surface of the cover, you will have to drill it. If you can keep it centered and not drill into the threads, a small EZ-out can remove it (once you get a hole drilled into the shank). If not, you can just drill out the entire shank, then fill with JBWeld metal-filled epoxy. After cured, put the headlight bezel in place and mark the center position of the 'missing hole'. Get a feel for the angle of the other hole and put a new hole/threads into the epoxy. You will need a 'bottoming' tap to do so. Good luck. 
Racer
Joined: Nov 2006
Posts: 435
Likes: 7
From: Wake Forest NC
Same thing happen to me. I took a q-tip soaked w/PB Blaster dabbed it on the broken recessed screws. Next day, I took an old machine scribe and small ballpeen on the outer radius of the screw, tapping it loose enough to grab it w/needlenose.
Racer
Joined: Apr 2003
Posts: 486
Likes: 0
From: Point Pleasant NJ
I've used the Pro GrabIts or whatever the official name is with very good success: LINK HERE. They even have micro ones, not that I've used those yet.
Yes, I've used ez outs before with a mixed bag of results. I'm not sure the overall difference but the grabits seem to have a really good bite with a lot less body of the screw.
I even used it to extract a couple of screws from the trim piece that connects the door metal to the interior panel without breaking the female side. You know, the ones with those crappy molded nuts in the plastic.
If you really have to drill out the main shaft and try to clean the threads you may be able to get away with putting the head of the screw back in by a thread or two and drill down the center of that as a guide. Still gonna be a
Good luck!
Yes, I've used ez outs before with a mixed bag of results. I'm not sure the overall difference but the grabits seem to have a really good bite with a lot less body of the screw.
I even used it to extract a couple of screws from the trim piece that connects the door metal to the interior panel without breaking the female side. You know, the ones with those crappy molded nuts in the plastic.
If you really have to drill out the main shaft and try to clean the threads you may be able to get away with putting the head of the screw back in by a thread or two and drill down the center of that as a guide. Still gonna be a
Good luck!
Race Director
Joined: Feb 2006
Posts: 12,239
Likes: 19
From: Chino CA
Also try a left handed drill (run motor in reverse of course !) run RPM VERY slow and push rather hard until it grabs...then it will want to unscrew...
Oh...PS - I HATE BROKEN FASTENERS !!!!!!!
good luck...
