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Old 09-05-2012, 08:41 PM   #1
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Help please! I'm desperate!

I just bought a pair of RI duallys and windshield brackets for my yellow 2000 TJ. All the parts arrived today and I attempted to install them. Needless to say the Torx screws on the hinges are shit. So I drove the 14 miles to the nearest home depot and bought a screw extractor. It striped after I got the passenger side done...

I was inpatient and went to try the drivers side and couldn't get it to save my life. So I made the hole bigger in hopes that I could use a bigger extractor in the set I bought because it wasn't stripped. Bottom line I drilled out the threads on one, ones out and, one has a gaping hole in it where i tried to fit the bigger extractor in.

I love my jeep to death and it almost made me wanna cry when I had seen what I had done. I need help to reverse the damage. I don't know what to do and everyone on here has always been so helpful in the past! :'(

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Old 09-05-2012, 08:57 PM   #2
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If it's broke you can always fix it. All is not lost and you are doing the right thing asking here. Basicly you just got in a hurry. You might have soaked the screws with liquid wrench for a day or two before you tried removing them. I got an 05 TJ and I haven't tried to remove any screws yet but I want to relocate my mirrors so I can take the door off next spring and I am sure I will run into the same problems. Anyway ask you local auto supply shop about helacoils, I think I spelled that right. It comes in a kit with instructions how to install. I'm not sure how much meat you got left on the body but you may have to weld them in or something like a threaded long nut. Don't panic next time. Look before you leap, it may take a little longer but how long is it taking now? You'll be OK, there are a lot of great people here and if my advise doesn't help I know someones will.

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Old 09-05-2012, 09:56 PM   #3
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Hard to figure exactly from this side of the internet, but can you drill out the remaining busted screw shanks and threads and tap those windshield nuts to the next larger size while retaining the integrity of the nuts? Real slow and lots of cutting oil, of course, if you can.
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Old 09-05-2012, 11:08 PM   #4
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Ok. I am a machinist and deal with things like this all day. What would really help in figuring a way to remove what's left is a picture. Post one up and hopefully I can help from there.

Also, helicoil is the way to go if u want to replace the one that u striped the threads out of.

If only u lived near Edmonton, AB I could prob have u going again in under half hour...but I'm willing to help u over the forum. So post up a pic for me and I'll give u step by step instructions on what to do. the better the pic the better I'll be able to help.

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Old 09-06-2012, 09:24 AM   #5
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Thanks everyone for the reassurance. Here is the picture of the bolt that I drilled the threads out of.
Here's the one that I drilled out. The screw extractor won't fit but i'm probably just going to buy a different size. So problem solved there.

Here's the far away view.

And here's what it's supposed to look like. It's the passenger side.
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Old 09-06-2012, 10:11 AM   #6
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Ya best bet for that one u drilled the threads out of is to get a helicoil kit. Make sure u get the right size for what u need. Best bet is to take in one of ur bolts that is still good just to make sure unless know 100% what size the bolt is.

Depending what size drill u used originally, u may have to redrill the hole to the proper size. Take ur time, and be safe.

On a side note....here's how u figure out what size drill u need if u r tapping a hole.

Imperial: (e.g. 1/2-13 bolt)

1/2 - 1/13 = .423

U need a drill bit .423 or as close as possible. In this case 27/64.


Metric: (e.g. 10mm x 1.25)

10 - 1.25 = 8.75mm

U need a 8.75mm drill bit in this case. To convert it to imperial:

8.75/25.4= .345"


Bryce
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Old 09-06-2012, 10:49 AM   #7
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I believe they are 5/16-18 screws. I just relaced some, myself, a few weeks ago. If memory serves, that's the size. They are not metric, and I was a little surprised since I haven't run across an SAE sized thread on any vehicle for quite some time.
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Old 09-06-2012, 12:39 PM   #8
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Alright how do you use these helicoils? I've never dealt with them
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Old 09-06-2012, 01:23 PM   #9
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Hmmmm. Haven't used in a long time. But u should have gotten a tap with them. U will drill out using the proper tap drill size. Then tap the hole. (Har har har) try to keep the drill and tap as perpendicular as possible to the surface you are going into. Take your time and use cutting fluid and make sure the drill doesn't get to hot!! And when u start the tap u can always use a square and keep checking it as u go.

Once tapped, u should just have to screw in the heli coil. The coil should end by the coil coming across the bottom of itself. If that makes sense. Where the coil comes across itself, this goes to the bottom so start threading this end in first.

And u should be done! Using red loctite is an idea to.

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Old 09-06-2012, 01:43 PM   #10
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Helicoils are not great actually. They work OK if needed but they are a little fragile. Try and get Timeserts if you can.
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Old 09-06-2012, 03:01 PM   #11
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Alright well the thing is its hallow inside there. I know it's hard to see in the picture. So will this still work?
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Old 09-06-2012, 04:48 PM   #12
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Hold on. New pictures.

Here's what the threads are supposed to look like.

And here's the one that I drilled wrong. I drilled to the sides. Part of the screw is still in the thread that I missed.
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Old 09-06-2012, 10:34 PM   #13
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Ok. First the one with part of the bolt threads still in it. How big is the hole in there now and how big is the hole needed for the tap for the helicoil? Cause if u need to still drill it bigger for the helicoil then u are ok.

As for the other one, is there anyway to get at the hole from behind also? That will determine some options if u can.

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Old 09-06-2012, 11:58 PM   #14
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I ****** rigged it. I'll probably take it to my cousins repair shop that way if he does anymore damage his malpractice insurance will buy me a new windshield. Haha. Thanks for all the help though guys. I really appreciate it.
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Old 09-07-2012, 07:38 AM   #15
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Sometimes it's best to know when to take it to a professional. Hope he has success. Good luck!

Bryce

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