Strut bracket screw sheered off

[jasonwantsout]

Hello,
I have an all terrain camper that the outside screw sheered off the strut bracket on the raised roof portion. ATC will remedy it, said it's about a 20 minute fix, but I'd have to cross Donner pass on I-80 to make Sacramento. I'm reluctantly willing, but weather has been bad enough that webcams show a road that is not entirely clear, lanes in the snow. Hate driving in those conditions. Anyway... I am not mechanically inclined, but is it possible to just back out that broken screw shaft (properly) and put another one on? Nothing inside to align or worry about? I would like to avoid the time, money and stress of going to them for a service issue if possible. But do not want to damage or goof it up further.


Any advice is greatly appreciated.

 

[jasonwantsout]

Thank you for the insight Verkstad.

Should I be concerned at all about driving? It stays on truck and that's my only vehicle. It won't stress that remaining screw under normal, on pavement conditions to the point of failure will it? I'm a worrier.

 

[chet6.7]

Can you post a close up picture?

 

[jasonwantsout]

Phone camera isn't very good, probably not the best lighting either. The remaining screw seems solid, not pulling away or crooked. But here's a couple pics if they help.
Greatly appreciate all the assistance. This is just recently received and I'd love to get back in it.

 

[simple]

What does it look like on the inside where the screw is?

 

[jasonwantsout]

They told me there's no fixing from inside. But it looks like this.

Can't tell from my wide angle view, but no inside access to it. That's all sealed up. It'd be there on the left, maybe behind that backing board, or just left of it but on the outside.
I just need to go to Sacramento. Knew if I had any problems it could be a hassle and an out of pocket expenditure to go. Not like their a chain with outlets everywhere. But I never heard or read a negative review of quality or durability.
That means more in the balance than any negatives.
Love the website,and appreciate the responses

 

[ExpoMike]

That top perimeter should be aluminum tubing, which is what the original screws, screw into. I would get the correct size sheet metal screws, pop the strut off the bracket. Line it back up and I would but two screws in those open holes, for 3 total. I would add the extra screws on all the other brackets as well. If one broke, it is likely others will at some future point.

 

[simple]

That is a good solution.

If I was doing it, depending on the thickness of the base material, I'd consider drilling and tapping the holes for stronger stainless machine screws with loctite. I'd be very careful not to break the other screws when backing them out.

Sheet metal screws are tricky when screwed into anything thicker than sheet metal. They like to bind and the hole diameter has to be just right. That screw might have been over torqued during install and been compromised from the start.

The broken screw could be drilled out from the outside starting with a smaller diameter drill in the center. A small diamond burr in a dremel might be needed to cut a center point in the broken screw to align the drill bit. Then step the drill size up as you go. It would help to have a full drill set with number and letter sizes. A little oil on the drill bit will help it cut.

Where it could go wrong is if you start with too large of a drill and have it walk off the side of the broken screw. It will want to plunge into the softer aluminum and bugger things up.


If you want, you could remove the gas strut for driving. It looks like the kind where you pop the clip out on the end and then it will separate from the ball. I'm not sure what the spring force is on those struts so you might want to remove it when it is extended. Have someone hold the top up so it doesn't fall.

 

[WOODY2]

Actually quite simple to remedy, rotate bracket back so hole is placed over broken screw then insert 2 new properly sized self tappers in the other two unused holes. Don't over tighten them. Should hold just fine.

 

[jasonwantsout]

Again, many thanks to everyone for your advice!