Door Bolt - Head Broke Off - Repair Help

[Sed_7]

Hey All,
One of the two bolts attaching the door to the nylon strap has broken off; the head broke clean off leaving the threads embedded. It seems like I have 2 options:

Option 1: using a screw extractor small enough to remove the threads
- anyone done this before and have any advice?

Option 2:

It looks like the previous owner had this happen to the passenger door as well and made two new holes with new screws, leaving the broken threads inside the door.
- If I go this route, anyone have advice on screw size, hole positioning, hole length? I hate the idea of drilling a new hole into this door.

Thanks for any help!

 

[chili_pepper]

Hey All,
One of the two bolts attaching the door to the nylon strap has broken off; the head broke clean off leaving the threads embedded. It seems like I have 2 options:

View attachment 562923
Option 1: using a screw extractor small enough to remove the threads
- anyone done this before and have any advice?

Option 2:

View attachment 562924

It looks like the previous owner had this happen to the passenger door as well and made two new holes with new screws, leaving the broken threads inside the door.
- If I go this route, anyone have advice on screw size, hole positioning, hole length? I hate the idea of drilling a new hole into this door.

Thanks for any help!

You may want to be careful with this. There's a reinforcement plate inside the door where those fasteners attach.

I purchased a set of used half doors earlier this year and the driver's door footman's loop (the thing that holds the check strap on the door) had been ripped out at least 4 times AFTER someone snapped the heads off both fasteners, attempted and failed to extract the broken ends, and then decided to create a new set of holes instead. The biggest issue with their attempted repair was that they were running screws into a single layer of sheet metal as opposed to the sheet metal and the reinforcing plate. The force of the door checking is too great for the fasteners to hold in the body sheet metal alone.

 

[DuckNut]

In my experience when you have good access to drill the broken bolt and use an extractor, it works great. When I don't have great access I usually swear at it, throw a few items at it for about a week. Then when I calm down I have it towed to a shop so they can beat on the POS for a few hours as well. I'm not selfish, I'll share.

 

[billyp]

I've never taken the door panel off my doors, but wondering if you did if you could get access to the end of the bolt from behind and twist it out?

 

[mrblaine]

I've never taken the door panel off my doors, but wondering if you did if you could get access to the end of the bolt from behind and twist it out?

You can do that. Not fun but you can sorta see the end of the screws.