Cab light help

[Thebrownturd]

My truck has factory cab lights with the raised light perches and welded in nuts to screw to; however, when I attempted to take the screws out a while back a lot of them broke off in the nut. Some of the nuts even twisted out of the metal and I am left with a square hole. I know the problem lies in the fact that sheet metal screws were used instead of machined screws and a little rust doesn't help either.

Does anyone have any good ideas on a fix? The PO twisted some of them to the side and drilled new holes but the problem with this is they are all cockeyed and facing random direction.

Could I drill out the twisted off screws that stuck in the nut and use a larger screws? What about the large square holes that have nothing to screw to?
Thanks for any advice. I need to figure something out before we go to paint.

[old Chevy guy]

If you could drill the holes out well, as in close to the center, you could retap them.. As far as the square holes I would try and get some nuts and tack them in with a mig. That's what I would do ,I'm not sure how your fixed as far as welding equipment or skills. You used to be able to buy square nuts,not sure if the still sell such a thing anymore. Is it going to a body shop for paint,maybe they could weld up the holes with new nuts.

[Thebrownturd]

I would like to weld nuts in but I think the metal is to thin due to feeling around with my finger and the rust pits that are visible in the area.

[Thebrownturd]

Originally Posted by old Chevy guy

If you could drill the holes out well, as in close to the center, you could retap them.. As far as the square holes I would try and get some nuts and tack them in with a mig. That's what I would do ,I'm not sure how your fixed as far as welding equipment or skills. You used to be able to buy square nuts,not sure if the still sell such a thing anymore. Is it going to a body shop for paint,maybe they could weld up the holes with new nuts.

I am painting it myself. I just worked out a deal with the collision center next to where I work trading some labor to use their booth and get some advice on painting.

[Jeff's bowtie's]

Try some JB weld fill the holes let it set up and drill a new hole not sure how it will work but worth a try if the metal is to thin to weld

[Gromit]

Just a reminder that left-handed drill bits can be helpful for drilling out stripped fasteners, provided you can get the drill bit started in the center of the bolt - probably not that easy in your case because you can't exactly whack that thin metal with a center punch..

I may not be using the right terminology.. these bits I'm thinking of spin counter-clockwise in stead of clockwise.

It sounds like it will still be a tough problem though.. maybe it would be easier in the long run to replace the roof skin?

[budman k20]

The cab light screws were not originally sheet metal screws. I would drill out the nuts or cut them out and glue in a new nut, maybe try welding a new one to some sheet metal. From memory the screw size was 8-32 or 10-32. Use one of the lens to size up the screw. Good luck... time to get creative!