Stephen70

I donīt know if this is a common problem, but some previous owner has ruined my 964īs front fender threads to install the headlight with one screw. Too much force used. As I donīt want to weld or solder anything to my car at this point, I created an easy fix. I used my Dremel mini-grinder to remove the old threads completely - so that all thatīs left is just a piece of metal with a hole through it. Some paint over the area where original threads were to prevent rust.

Then, I cutted a small piece of stainless sheetmetal, drilled a 5 mm hole, and silver-soldered a square-edged stainless nut to the sheetmetal. Just a bit more cutting and sanding and bending... and hereīs a result. Works very well.

PhatPhlatSix

Good job! Do you think JB Weld would have worked for those without brazing/welding facilities?

Stephen70

Surely - except that if JB Weld would have been used, I would tighten the screw very, very carefully. If the nut gets loose when the headlight and screw is attached, removal of headlight can be a real nightmare.

ToreB

Nice!
Tore

Rocket Rob

Great job. Did you have to use a longer screw afterwards? I did when I repaired mine. I used a rivet nut instead but your solution looks good too.

Stephen70

No, original screw is just long enough. I also had a rivet nut in mind, anyway I had no luck to locate one - and I had to get it done as driving season is about to start here in Scandinavia shortly.

FeralComprehension

Nicely done!

I think a dab of corrosion-protectant is a good idea here; I use CorrosionX but there are alternatives.

P356GT

Always nice to see other solutions to a problem :-)
I used a rivet version.....my lazy way to fix it.....
But your solution can be useful in other places that are in a enviroment with salt and mud

TeeJay78

Nice. This is just what I was looking for. But I will look for such a rivet nut mentioned by Rob.

964russ

Rivnut