Newb How to ?: strepped sheet metal

[Ybviking]

Hi all
Total newbie to the wonderfully frightening world of D90 ownership ( 1994 D90, UK RHD)

I’ve noticed a few of the exterior screws - which are surprisingly non-rusty have no grab. The sheet metal is stripped. So far, it’s marker lights and reflectors

What’s the “fix” you all use? I’m thinking a correct sized screw clip ought to do it, but you all might have a better way

 

[MountainD]

If it has a screw clip, often times using pliers to bend down the tang works fine.

 

[Ybviking]

Thanks @MountainD

These are screws going thru flat body panels. Look like they were placed with a impact driver and stripped. I thought of just backing it up with a clip. Would like to avoid upsizing the screw

 

[erover82]

Yeah, often these are missing, corroded, or worn.

On later models, LR switched to using these (RTC3745):

The hole pattern changed too, but they can be retrofitted with a drill and square file. They're a better design in that they eliminate oxidation and galvanic corrosion.

 

[erover82]

If you're looking at the side repeaters on a 94, they should have plastic spikes that press into chintzy little bushings.

 

[erover82]

If you're referring to these reflectors, yeah they use self-tappers - not the best idea. I'd make the holes square and switch to RTC374, or small plastic rivets.

 

[Ybviking]

If you're referring to these reflectors, yeah they use self-tappers - not the best idea. I'd make the holes square and switch to RTC374, or small plastic rivets.
View attachment 28353

Yes this is one of the culprits! If - and that’sa big if- i can get one behind the sheet metal I’ll just use a clip since the part probably won’t be removed in the future

The other is the front marker light lens is cracked at the hole- I’ll switch this out to that rtc374 as this will need to be removed from time to time - probably when I get to doing the led change over

 

[WreckITFrank]

Marker lights are often replaced so usually everyone has a stash. Post up what you need, someone will likely have it.

 

[Ybviking]

Ok thanks all. Managed to get a “good enough “ bite that I should be ok…. For now. 🥹

And of course the led headlights would only light on high beam only or low beam only ( using an H4 adapter….. . So instead of sorting it through, just bought new h4 bulbs. But i see the supply is limited to 8.2/8.4 volts. Is this normal?

Whats the troubleshooting line to chase that gremlin? Low is mighty dim. I expect an unusual amount of abuse from the community as I’m still “the new guy”

 

[evilfij]

Headlight switches melt. Add a relay kit.

 

[Ybviking]

This seems to be the culprit(s)

Next question: do I open a line of credit or stick with one-off ordering from RN/BritPart/Paddocks ?

Thanks will post findings and fix results as they happen

 

[erover82]

But i see the supply is limited to 8.2/8.4 volts. Is this normal?

Not normal, even under load. As evilfij said, often the switch, but problem(s) could be at other locations in the harness connections too. If you stick with halogen, then a relay kit will improve reliability and brightness. LED headlamps are an alternative too. More expensive, but simpler and even brighter. I’d recommend the Holley Retrobright.