Windshield repair problem...

[Rusty nuts]

When I picked up my Deuce both front windows were sealed shut with silicone. Today I started cutting them back open and removing them to replace the glass on the passenger side and put new rubber on them. Well the drivers side top hinge was being held on by one bolt after removing the silicone, all the others were broke off. Go to remove the last bolt and it snapped off I thought the windshield frame would be tapped for the screws, but there looks to be a plate inside that is now loose inside the frame. Checked the TM's and o info, so I assume the plates are put in when the frames are built. I will be running a soft top and looking at the frame, it looks like the only thing I can do at this point is to drill the holes out through the top of the frame and use a bolt like a button head Allen all the way through. Now I'm sure this has happened to people before but could not come up with anything in searches here or at Google. Any other ideas or ways to fix this?

 

[goldneagle]

Here are a few suggestions:

1-Why not just use self tapping screws next to the existing holes. You can drill new holes in the hinge first (slightly larger than the screws).

2-Replace the outer frame.

3-Use a Nut/thread riveter to insert threaded inserts into the holes and then use machine screws to attach the windows back.

 

[Rusty nuts]

Here are a few suggestions:

1-Why not just use self tapping screws next to the existing holes. You can drill new holes in the hinge first (slightly larger than the screws)

2-Replace the outer frame.

3-Use a Nut/thread riveter to insert threaded inserts into the holes and then use machine screws to attach the windows back.

1. Actually, I could just use a sheet metal screw in the existing hole as they are not that big to begin with. With the plate inside loose, there is a good clean hole. I was just trying to over think it.

2. The rest of he outer frame is in great condition.

3. Thought about a nutsert, but the Addams little thickness and would set he rest of the hinge off the frame.

I just wanted to see if there was any way of getting inside the frame that I was over looking.

 

[gringeltaube]

..................I just wanted to see if there was any way of getting inside the frame that I was over looking.

With all 7 WS-hinge screws removed, (normally) that inner plate would still stay in place, via two rivets. (hinge comes notched for that reason).
Sounds like those two rivets were missing, or sheared off, too...?


In order to keep the original pattern for the WS hinge screws I would try this:

1) Use a self-tapping (auxiliary)screw, long enough to go all the way down through the frame's top face. With that one screwed-in, the plate would have to come to rest firmly in place; ideally, in the exact original position, for the old holes to be re-drilled & tapped. (Maybe use an awl and a bit poking-through-holes, to get it sitting at the right spot again.

2) Re-drill & tap (3/16"-32 thread) the one- or two- original holes, closest to where the aux. screw is pressing down the plate. Put (hinge)screws in place after each hole is finished. One-by-one, work your way forward until all 7 screw holes are done.

3) Remove all screws and use compressed air to blow out shavings, dust, etc...

4) To keep the plate from ever shifting again: a) inject plenty of PU adhesive/ sealant through all of the lower existing frame holes and screw-in top screw, then the hinge screws to bring plate into position. With all screws in place, wipe off any excess sealant (while fresh) and let cure for 24h.
Or b): replace those two rivets.


Good luck!


G.