I found an older thread on this subject on a Google search so I thought I would pose my own conundrum. It’s not a factual question, but hopefully someone can help as with the previous poster.
I have a screw hole in my metal shower door that has apparently become too big for the screw. It was fine until I recently removed it to install a new shower sweep. I believe I have already gone to the largest screw I can possibly use in this door (this has happened before). Beyond replacing the entire door or drilling new holes, what can I do? I don’t have a drill powerful enough to drill into metal.
Are you sure? Have you tried? I was surprised how my wood drills were able to go into metal. It’s not easy, and I had to push hard, and the drill wore out long before its time, but it got the job done.
Does this screw go into formed sheet metal, or into threads cut into a solid piece of metal?
If it’s solid metal, there are a lot of options…cutting new (larger) threads with a tap & die, using two-part epoxy “form-a-thread” or threaded inserts to restore the original thread size, etc. These are pretty common automotive solutions and they might be overkill for this application, but if it’s holding up the weight of the door, maybe not.
This doesn’t make sense to me, as every electric (plug-in or cordless) drill I’ve seen can handle drilling into metal, and will take care of aluminum or sheet steel with ease. It’s the drill bit that makes the difference. A standard bit designed for metal (easy to find) that is sharp should drill into it just fine.
I think that I know exactly the problem you’re having. I understand your question to mean that you have a glass shower door with a metal frame around the glass. Is this correct?
If so, my recommended ‘fix’ for this is the same as SpeedwayRyan’s suggestion, ie: using two-part epoxy “form-a-thread”.
I have used this method to repair similar problems, myself.
if the sweep is attached to a hollow metal channel then a sheet metal screw will cut its own threads into it. you upsize the screw.
you could also, if a hollow metal channel and a sheet metal screw, mix up a pea sized bit of epoxy or plastic filler, place it on the existing screw(near the head) and put in place (last after the other screws). let the stuff harden. it should hold the screw hard enough yet still allow the screw to be broken free later.
Quoted for truth. Get a new drill bit. A twist bit like the one pictured is what you’re looking for, and every single one of those on the market should be rated to drill through metals. Just don’t get a masonry bit , or spade bit, or any other fancy wood specific bit.
Sometimes you can replace a stripped screw with a machine screw and nut, if you can get to both sides of the join. You can also use a tee nut (the kind used to give a blind permanent “nut” in wood, like Ikea furniture) and a machine screw.
Not a direct answer but may help someone else: if you have a screw strip out in wood, such as for a door hinge, drill out the stripped hole to 1/4 or 3/8 inch (or, if you have a complete set of bits, to 15/64 or 23/24). Using wood glue, drive in a length of 1/4 or 3/8 hardwood dowel. The face cut should be as smooth as you can make it and the length long enough to go through the jamb or stud. Tap it in just flat. Let dry. Sand or scrape smooth. Drill a new pilot hole and replace the screw.
Something else on the market is called a nutsert. It is used for installing machine threaded nut locked on to sheet metal by a crimping process. They probably cost about $20.00 but can be used for ever. They come in quite a few sizes. The proper size drill and crimping tool come in the kit.
Any kind of adhesive that will 1)stick to the metal and 2)fill up some of the hole when it dries with 3)a sufficiently tough solid material should do the job. Epoxy (as mentioned earlier) is a promising candidate.
I’ve never had much luck trying to run screws into epoxy etc. if they had any kind of load on them at all. If it’s mostly cosmetic and the strain on the screw is modest, a glob of metal-compatible epoxy (usually gray/silver) in the hole, with the screw run in carefully as it’s mostly hardened, and then tape or some other support to hold the screw and trim in place until the epoxy sets… might work.
Nutserts are used for installing mirrors for instance on the door of a car where no solid metal can be located. They are commonly used on tubing and sheet metal projects where strong screws are needed.
