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  #1  
Old 05-23-2013
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!@#$ 5200!!

I tried to finish what I thought would be an EASY project, but to no avail.

Deck-mounted starboard nav light was out, so I tried to remove the three screws that held the lense in place. Easy-peezy, right? Nope- the screws have apparently been bedded in with 5200, because they aren't budging.

One screwhead broke off, one will only work loose a little, and one won't budge at all. I tried Dremeling out a slot on the heads so that I could use a big flat head screwdriver, but that didn't work either.
So what to do now? Drill out the screws with a titanium bit?? That is the only thing I think might work.
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Old 05-23-2013
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Re: !@#$ 5200!!

Have any photos of these fixtures? Are you certain that they aren't thru-bolted with nuts on the back?
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Old 05-23-2013
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Re: !@#$ 5200!!

Drill the screws out, refill the hole, and then drill and set it properly.
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Re: !@#$ 5200!!

Definitely not-through bolted. Going to drill 'em out.
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Old 05-23-2013
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Re: !@#$ 5200!!

TNT aka dyno-mite?

drill & fill.
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Old 05-23-2013
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Re: !@#$ 5200!!

How does one keep the drill bit on the hard steel screw shaft when all the soft fiber-glass is so close?

It's not like you'd start with a smooth steel face that you can use a set punch on. The bit just wanders off the steel and into the FG. Maybe drill many holes with a smaller bit all the way around until the leftover screw piece falls out from sheer boredom? Then re-drill even bigger, fill and finally drill to size?

I got tired just typing that!

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Old 05-23-2013
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Re: !@#$ 5200!!

drill around it and dig it out then re fill with epoxy and re drill for the screws. done it many times
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Old 05-23-2013
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Re: !@#$ 5200!!

You've those crappy little half round stainless steel doeys (like Perko back then) that sit on the stemhead casting??? http://www.perko.com/catalog/categor...rs/product/76/
They are definitely screwed in and generic replacements are available. 36 years is a good lifecycle for these. A nice new matched pair will be reliable and polish up your bow area.
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Re: !@#$ 5200!!

You can buy a drill guide if it HAS to be precise... but they aren't worth it in my opinion. Drill around it if the area can be covered by the hardware and refill it all. OR, drill at high speed with light pressure and hold it really steady.
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Old 05-24-2013
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Re: !@#$ 5200!!

Rugosa, that is the EXACT same light that I am dealing with. Would like to eventually go to LED.
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