coach door seal
I should have made it coach door seal fiasco but want it to be searchable.
I finally got around to getting rid of the broken white door seal and messaged Bruce (bbeane) as he had done his. His first advice was that it weighed around 120 lbs. and I would be getting broken screws in the process. I also wanted to reseal the door screen so I called PTL and ordered the screen door seal parts knowing I still had a new PTL door seal from when I ordered 2 for my Monaco.
Removed the A-pillar side of the hinge and put the door on saw horses and started removing screws on the door side of the hinge. Marked the long screw holes and thought the short screws would just go in the other holes. Wrong, the short screws were broken screws, lots of broken screws. Tried to drill out the broken screws with my cobalt and titanium drill bits. Didn't work screws too hard. Ordered Carbide drill bits from Grainger 3 days later found out they wouldn't work. decided to just drill new holes altogether and found out the hinge is some kind of hardened steel that the carbide only scratches. Final try, the holes were oblong so put self tapping # 8 sheet metal screws on the opposite side of the slots on the hinge. That worked. The Monaco seal wound up being 1: too long and 1" too wide so trimmed and glued to make fit. The door is back on this morning and I will deal with the screen door tomorrow.
Pictures show the ratio of broken screws vs good screws. and solution to putting screws back in and the part number for carbide 9/64 bits that didn't work for this project but nice to have for other things.
Topic: coach door seal