Door Panel Screw Removal

[ol Curt]

I have two screws from my inner door panel that broke off. I have soaked the in penetrating oil and tried to drill them out...broken two bits. I don't know if there is enough left to get an easy out on them...but man they are in there. I'm looking for ideas. I'm thinking of grinding the end off and trying to re-drill. Any ideas?

I also lubed the window hardware, and it rolls very easy till it hits one spot where the window is almost up. Is it difficult to take the things out and clean them up? I suspect the most difficult part is getting the window glass out.

[tommys69/454]

grind it flat and use a center drill in a hand drill. these are in regular use in all machine shops and any machine tool supply place. they are sized by numbers and I would say you need a #0. In any case you need to have the pilot smaller than the minor diameter of the thread. then if necessary you will easily be able to use a drill bit.

[jonzcustomshop]

I had some very rusty ones on a 63 door, head was broken off, I took a small washer, and welded it to what was left of the screw, then took a nut, and welded that to the washer, took a wrench to it , and it came right out.

the heat from the welding is the big thing, it boils out whatever moisture is left in the rust, and expands the bolt, when it cools off it has usually broken fre of the threads, sometimes it helps to squitr a little water on the threads right after you heat it up, this causes it to contract quickly and helps it to break free.

[TheDark1]

I had several that I had broken off over the years and I had knocked the square nut off on a few. At the time I didn't have access to a welder, so I used the little plastic nuts that you use for the licence plate in thier place. They just pop in and are still in there years later. If you only need a few on each door, this should work just fine.

[ol Curt]

The last method worked best for me! As always thanks for the help guys!!