samurai_k

If you are having a few issues getting messed up screws out, try a dremel with a cut off wheel and if enough space behind the head of the bolt you can cut the head off easily or attack the head of the screw.

If no space then drill off the head.. hold the screw head with some needle nose vise grips or equivalent. Not sure if the hardware is hardened, but if your drill bits are not doing well, then a hardened drill bit may be needed. Milwaukee has a "hardened" line of bits that work well you can get at your local big box home improvement center.

Paolo1

Those are great ideas. Thank you. This is humbling.

Paolo1

I imagine when the offending screw and old dead pedal are out, I would just use new screws with just slightly larger diameter.

pp000830

A good way to improve the ease of drilling is to use a good cutting tool brand of drill bit purchased at an industrial supply store. A 135° Split Point – Starts on contact in metal and eliminates “walking” .The industrial brands are sharper, have better formed cutting edges and annealed shanks that flex without shattering so they last a lot longer in service drilling applications then drills purchased at Harbor Freight or most DIY stores. I never knew the difference until I got a set as a gift where they were much easier and faster to use and lasted for years.

Andy

Paolo1

...but, for the sake of argument, if it were bolted from behind the footrest sheetmetal, how would I access it?? thank you for indulging me.

Paolo1

Is there a diagram somewhere to help visualize the footrest from the backside ? I don't see it in the parts catalog...

Paolo1

Well I broke out the Dremel and had to sacrifice the old dead pedal in cutting off the screws head. The remaining screw is definitely bolted from behind. I can feel it. The adventure continues.

samurai_k

Have you tried to open up the black plastic door next to the AC lines in the driver side wheel well?