TheSamba.com :: View topic - Help! Filler plugged side mirror holes

Sat Jun 16, 2012 10:04 pm

Hi Folks,

I recently purchased a '71 campmobile that is in really great shape, and am slowly but surely getting her ready for the road.

Somewhere down the line, some P.O. decided that it would be a good idea to scrap the stock side mirrors and replaced then with some god awful oversized models. Sadly, they plugged the side mirror holes, sanded them, and painted them to match the rest of the body.

As this must have happened quite some time ago, I can just make out where the holes should be. It's my understanding that this hole is threaded to accept the mirror post, so I'm a little hesitant to just try and drill it out.

Any suggestions on how to clear this hole and preserve the threads? Is there some magic way to just make body filler disappear? I'd really like to ditch these mirrors and go back to stock...

Thanks for the help!

Sat Jun 16, 2012 10:08 pm

I guess you could run a magnet around the area til you feel the strength of it change, then decide from there

Sat Jun 16, 2012 10:19 pm

drill it out starting with a small drill bit as centered as you can and then start using progressively larger drill bits until you just tag metal. then get in there with picks and maybe even a big tap for the hole

thats what i would do

Sat Jun 16, 2012 11:31 pm

I do have a pretty good idea of where the holes are...theres a faint rust circle outline showing underneath the topcoat.

Do you think that I could tap the hole out to the same size that it already was?...Thought that I would have to go bigger in that case.

Sun Jun 17, 2012 2:45 am

zonxs7 wrote:
Do you think that I could tap the hole out to the same size that it already was?...Thought that I would have to go bigger in that case.

I'm not sure what you mean here. The hole is threaded like you said so you definitely don't need to make it larger than originally was. Just get in there and start drilling and chiseling that junk out of there. Do it like rustbus suggested. Be careful not to damage the threads.

Sun Jun 17, 2012 8:05 am

Use the tap to clear the bondo out of the threads, not to re-tap the threads. Like he said, drill out as much bondo as you can without getting into the threads then make sure you you have the right size tap for the threads in question. Go in a little at a time, then back out and remove the debris. Repeat as needed.

Sun Jun 17, 2012 8:10 am

If it is bondo you might be able to drill it in the center to a reasonable size. Use an thick exacto knife or box opener (non-breaking kind with metal handle) to cut the paint and bondo a little at the surface to be sure it doesn't rip out any paint. Then try an easy out in the bondo plug to see if you can work it loose. It may unscrew. If not then drilling and re-tap is all you can do. Let's hope he didn't weld the holes.

Sun Jun 17, 2012 8:13 am

rustbus wrote: drill it out starting with a small drill bit as centered as you can and then start using progressively larger drill bits until you just tag metal. then get in there with picks and maybe even a big tap for the hole

thats what i would do

Me too.

Sun Jun 17, 2012 8:45 am

Yep. Small drill just through filler. Then scrape and pick by hand with small sharp things. There may be some kind of stiff wire brush to go on your drill.... like a hardcore bottle brush. Otherwise, you're picking by hand. Good idea about using a tap to gently clean out the threads, by hand, once you are almost done.

Sun Jun 17, 2012 8:59 am

you may be able to EASYOUT the bondo if your lucky....try drilling a smallish hole, and cuting the surface of the paint (someone already said that) then using an easy out to back it out like a screw....

or do what everyone else says and just get the majority out, the chase the treads with a tap.

Sun Jun 17, 2012 9:19 am

I wonder if there is some way you could pop your door panel off and get it from behind. It would probably take some dexterity but it might work.