I've started a new thread as last one was under "wanted" so didn't want to miss out on any advice because of that.
Short version (story not rails) …
took short rails off to fit long ones … near side rear bolt broke in the hole.
drilled it out (took ages) and started using 6mm tap in the hole. that broke … hindsight I knew it was brittle but trying to get job finished, i'm sure you know what it's like.
many hours of careful drilling and tap is gone … removed is wrong word. it's now dust.
cleared hole and filled it with metal repair epoxy stuff.
drilled ~6mm hole in that and tapped it to 6mm …. top end wasn't too good so partially helicoiled it.
all seemed well as I had a bolt in it and it was deffo fixed and tightened up nicely.
put rail in place, squirt thread-lock stuff into holes and on threads, tighten up and … spins.
can anyone suggest a way forward ? did i just not leave the epoxy long enough ? (it was chuffing cold today but i left it an hour or so)
TIA..
Dean
====================================
2011 D4 XS - OBD port protection, RLD spare wheel protector, All LED interiors lights, Timed Climate enabled, iiD tool paired.
2011 D4 Landmark - Stolen from same dealer before I paid for it
2011 D4 GS - Stolen whilst at dealer ... All LED interiors lights, DRLs, Spare Wheel protector.
1996 300Tdi - Eaten by tin worms
Last edited by Hardware on 7th Mar 2018 5:27 pm. Edited 1 time in total
15th Feb 2018 6:18 pm
philm
Member Since: 02 Oct 2016
Location: Manchester
Posts: 732
I have some industrial plastic metal if you would like to come and do it.L633 Defender
Range Rover Velar-gone
Discovery 4 Landmark-gone
Gap IID Tool
15th Feb 2018 6:58 pm
Grease Monkey
Member Since: 24 May 2009
Location: Essex
Posts: 134
Hi Dean
I'm pretty sure you can replace the stud that has the stripped thread, you'll need to dig out the sealant from around the stud, underneath you should find a hex nut. Just undo and refit new stud and reseal. I had this on one of my front fixings. Microcat shows eight fitted to roof, so four per side sounds about right.
Part number is AYR500061
Hope this helps
Matt2009 D4 Zermatt Silver SE (Pre-Production) - Current
2014 FL2 Santorini Black HSE - Current
2009 FL2 Zermatt Silver XS - Gone
2005 D3 Zambezi Silver S (ex Bigdave) - Gone
2005 D3 Zambezi Silver SE - Gone
I'm pretty sure you can replace the stud that has the stripped thread, you'll need to dig out the sealant from around the stud, underneath you should find a hex nut. Just undo and refit new stud and reseal. I had this on one of my front fixings. Microcat shows eight fitted to roof, so four per side sounds about right.
Part number is AYR500061
Hope this helps
Matt
oh ! on mine it looks suspiciously like something flat welded to the roof but with all the sealant on it you may be right.
Dilemma now !
problem is I've told SWMBO it's sorted, so using the epoxy from Philm might be do-able without letting on that i'm still doing this !
15th Feb 2018 8:25 pm
philm
Member Since: 02 Oct 2016
Location: Manchester
Posts: 732
Would a rivnut do it? also got some of them if you want to try.L633 Defender
Range Rover Velar-gone
Discovery 4 Landmark-gone
Gap IID Tool
and i'll pop over to Philm's later for the temp fix epoxy.
only concern is that when I had a stud extractor in the broken bolt, it showed no signs of the underlying stud moving … which is why i was convinced it was welded.
thankfully the mayhem due to rugby traffic had calmed down a bit on the way home … and i got to try the new "divert everyone to the Trafford Centre" bridge
16th Feb 2018 8:52 pm
philm
Member Since: 02 Oct 2016
Location: Manchester
Posts: 732
Nice to meet you, hope you get it sorted.L633 Defender
Range Rover Velar-gone
Discovery 4 Landmark-gone
Gap IID Tool
ish …. Phil's industrial strength epoxy is now holding a bolt in place that will at least minimise any movement until i get back from Devon next week. By then the replacement part from Dan will have arrived and i'll use that to fix it properly. well, that's my theory at least.
18th Feb 2018 12:53 pm
df_tom
Member Since: 10 Mar 2017
Location: Stuttgart
Posts: 127
if there's enough metal left, a thread insert might also work.
i think the helicoil failed because the new type aren't square section stainless wire as per the originals and it didn't get enough grip into the AYR500061 stud.
i'm confident that if/when i get the old stud out i'll be ok. just finding time whilst SWMBO's not about with reminders that i'm about 20 hours into a 1 hour job so far
18th Feb 2018 1:39 pm
Grianaig
Member Since: 08 Jul 2014
Location: Tyne and Wear
Posts: 1286
Sympathy concerning SWMBO’s ‘interest’ in your attempts. For a long time, on every occasion when I say this will only take ten minutes, there are howls of laughter and the comment, “I’ve heard that before”. Trouble is she is always right.
Best of luck with the repair. 2014 MY Discovery XS Indus Silver. Sadly gone. Second last LR of forty eight years continuous ownership.
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spins.
... All LED interiors lights, DRLs, Spare Wheel protector.
