Oversize Holes
Thread Starter
Melting Slicks
Joined: May 2015
Posts: 2,365
Likes: 428
From: Cape Girardeau Missouri
Oversize Holes
'79
All three of the mounting holes for the screws that hold the trim panel to the driver door are slightly too large. While the screws seem to grab properly upon installation after even a short time on the road they are all quite loose.
I know the old trick of steel wool for slightly loose connections in a bolt/nut type situation but don't know what to do for sheet metal.
Any suggestions?
BTW, I replaced all of the interior screws and they hold fine in the passenger door so I know that that the screws themselves are not the problem.
All three of the mounting holes for the screws that hold the trim panel to the driver door are slightly too large. While the screws seem to grab properly upon installation after even a short time on the road they are all quite loose.
I know the old trick of steel wool for slightly loose connections in a bolt/nut type situation but don't know what to do for sheet metal.
Any suggestions?
BTW, I replaced all of the interior screws and they hold fine in the passenger door so I know that that the screws themselves are not the problem.
Race Director
Joined: Apr 2011
Posts: 11,183
Likes: 3,334
From: North of Toronto - Ontario
If they're close (not too much over) and in the steel panel you can usually go around the edge of the hole (maybe 1/16th away from the hole) with a center punch and put about 6-8 "dents" around (automatic center punch) each hole. This will force some of the metal back into the hole and close it up.
If it's more, you really need to get into adding a small piece of tin to the back side of the skin (pre-drill and epoxy it in place) or a u-clip type speed nut may work
M
If it's more, you really need to get into adding a small piece of tin to the back side of the skin (pre-drill and epoxy it in place) or a u-clip type speed nut may work
M
Burning Brakes
Joined: Oct 2006
Posts: 1,089
Likes: 43
From: Native Californian CALIFORNIA
Army
There are many ways to tackle this issue:
JB Weld the hole to make it smaller
JB Weld a blindnut behind the hole
Pop rivet some virgn sheet metal behind the enlarged hole, pre drill the new hole
JB Weld the hole to make it smaller
JB Weld a blindnut behind the hole
Pop rivet some virgn sheet metal behind the enlarged hole, pre drill the new hole
Burning Brakes
Joined: Jul 2015
Posts: 823
Likes: 57
From: Austin TX
That last one gets my vote, and make sure the new metal is a gauge or two thicker than original. You could also attach the new metal with JB Weld or by soldering or brazing.
Last edited by 454Luvr; Jan 2, 2016 at 06:05 PM.
Pro
Joined: Oct 2000
Posts: 558
Likes: 22
From: Vancouver, B.C., Canada
Here's what I do. Take a small piece of bailing wire, bent 90 degrees, and stick/hook it in the hole. Now mount the panel and screw it down. This makes the hole just a little bit smaller and gives the screw something to "bite" into. Usually works for me.
Le Mans Master
Joined: Sep 2003
Posts: 8,812
Likes: 2,029
From: eastern NC
I learned this trick from my Father back in the 60's. He always used a piece of copper wire however. He said it was softer and would conform to the screw easier and there was less of a problem with corrosion.Good luck... GUSTO
Thread Starter
Melting Slicks
Joined: May 2015
Posts: 2,365
Likes: 428
From: Cape Girardeau Missouri
Thanks for the wire idea!
No offense to the others, but that sounds like the most practical--especially for the upper rear hole with almost zero access to be back side.
No offense to the others, but that sounds like the most practical--especially for the upper rear hole with almost zero access to be back side.
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Burning Brakes
Joined: Jan 2009
Posts: 766
Likes: 97
From: Lake Norman, NC
FWIW, I have the luxury of having a great fastener shop not far from my office. There, they stock many, many fasteners, including sheet metal screws with a smaller head size than normal for the body of the screw. For example, if I have an oversized hole problem with a size 6 screw, I can buy a size 8 screw with a size 6 head. This shop can almost always match the type head and proper plating, thereby making the repair invisible with no extra work.
From first hand experience, I know this is how the assembly plant made corrections like this. They used what is commonly termed a "repair" bolt/screw/etc.
Hope this helps...
From first hand experience, I know this is how the assembly plant made corrections like this. They used what is commonly termed a "repair" bolt/screw/etc.
Hope this helps...
Thread Starter
Melting Slicks
Joined: May 2015
Posts: 2,365
Likes: 428
From: Cape Girardeau Missouri
It's been a while since I posted this but I finally decided to try this fix after the front screw for the arm/rest door pull also came loose and refused to hold. It was simple and worked BEAUTIFULLY. Thanks!!!! I used 16 gauge aluminum wire.
Melting Slicks
Joined: Oct 2003
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From: Chapel Hill NC
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I have some success with plastic drywall expansion anchors
Pro
Joined: Oct 2000
Posts: 558
Likes: 22
From: Vancouver, B.C., Canada
Your welcome. Pretty simple but it usually works.