There is now a small hole in my roof!

[Marcus Aurelius]

Well, the other day i was removing some of the parts on the explorer to get it ready to clay bar; license plates, plastic trim piece around antenna, plastic piece with emblem on tailgate, and roof rack.

I have done it so many times before when cleaning because dirts gets trapped behind it. So, I was putting the 10 bolts for the roof rack tracks back on. I put the drill on a low torque setting and screwed them in. It didn't seem to be enough and it was the first time I used my new drill to do this. So I kept tightening the torque setting.

BAD IDEA. I tightened a bolt too far. It ended up loosening the copper piece that was probably welded onto the roof that the screw goes in. It also slightly bent the sheet metal. So then the screw was in there tight and the opposing threads moved freely with the screw as I turned it, but they both wouldn't come out.

I ended up using a wrench to hold the copper piece in place while I unscrew it. It worked, left some nice deep scratches around it. With the screw out of the way, I as able to reshape the slightly bent sheet metal. I also bought some touch-up paint and clear-coat the fix the scratches.

But, the surrounding is still loose. I can put the bolt in to cover that hole, but it is likely to get stuck again and it dosen't completely solve the problem.

What can I do to make the threaded hole that the screw goes into stay in place?
Thanks

I would post pictures, but the memory card drive in my computer isn't working.

 

[J_C]

I don't know what the piece you are referring to looks like, but generally you would either weld it back on, or drill new holes in it and the roof to attach to the roof with sheet metal screws (with rubber gasket/washers on them so water won't get in the roof).

Similarly, if there is a hole in your roof where water could get in you will need to fill that hole, if it is small you might be able to just bondo it, or if large you will need some screening or sheet metal added. If it is completely covered by the rack and you want the cheap easy fix, you might be able to fill the hole with silicone caulking instead, since it wouldn't need painted. Pictures would help.

 

[scucci]

Maybe a rivet nut? up to 1/4" available at horrible freight along with the rivetnut installer.
http://www.harborfreight.com/45-piece-threaded-insert-riveter-kit-1210.html
or
http://www.fastenersuperstore.com/s...ory=Rivet Nuts (Threaded Inserts)&stage=step3

 

[IZwack]

JB weld - clean the surface, apply, let it set, drill, and tap. Obviously, install the screw with less torque than normal.

 

[ncranchero]

Maybe a rivet nut? up to 1/4" available at horrible freight along with the rivetnut installer.
http://www.harborfreight.com/45-piece-threaded-insert-riveter-kit-1210.html
or
http://www.fastenersuperstore.com/s...ory=Rivet Nuts (Threaded Inserts)&stage=step3

Most ARE Rivnuts/Nutserts/etc. Most body shops would have a set with the installation tool.

 

[J_C]

JB weld - clean the surface, apply, let it set, drill, and tap. Obviously, install the screw with less torque than normal.

Is there a trick to tapping JBWeld? I can tap most materials fine, and use JBWeld a lot, but I can never keep the threads from chipping off when tapping it, or later, and I have even tried extended hardening time (a couple days wait).

 

[gmanpaint]

Why not just use a larger panhead sheet metal screw? Just use one that is the right length & wide enough to bite.