Jalousie window frame....grrrrr...... - Fiberglass RV


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Old 07-12-2013, 11:40 PM   #1
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Name: Jan
Trailer: Boler 1978
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Jalousie window frame....grrrrr......

Decided to replace cracked side window on the Boler today. Removed the frame easily enough from the assembly. Robertson screws...gotta love 'em!

This is where it gets interesting. Since it's a '78 Boler, I'm assuming none of the fasteners for the window frame have ever been removed, so I sprayed my secret formula of WD40 and PB Blaster on the fasteners to penetrate for a while.

They came out just fine....except for the two located at the bottom of the vertical frame section frame which I assumed were a little more stubborn because I thought the were corroded more. Applied more WD40 and PB Blaster and wait.

Armed with my trusty #1 Robertson screwdriver I used more torque. No luck. And ended up rounding out the screw head.

Tried a screw extractor, then drilled out the screw head, then tapped the frame end of only discover this:

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It's about 1 3/8 of an inch long!

This end shows the regular screw, about 5/8 of an inch:

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Question now is: How to fix this and reassemble everything successfully?
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Old 07-13-2013, 12:14 AM   #2
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Hummm, I really can't help except to encourage you to do whatever you can to save those WONDERFUL Jalousie windows!! Maybe use some alumaweld in the hole and redrill? Other than that, the best I can offer is a great thread from Dannyh with information and links to necessary parts for rebuilding: DannyH's Jalousie Window Rebuild
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Old 07-13-2013, 06:31 AM   #3
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Didn't someone recently have this same problem and got the screw out by slightly spreading the groove it is in. Some penetrating oil may also help, a small punch or old screw driver on the inner end to hammer it after spreading the groove. Or a thin cutting disc on a die grinder or moto tool and grind it away.
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Old 07-13-2013, 09:32 AM   #4
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Quote:
Originally Posted by mary and bob View Post
Didn't someone recently have this same problem and got the screw out by slightly spreading the groove it is in. Some penetrating oil may also help, a small punch or old screw driver on the inner end to hammer it after spreading the groove. Or a thin cutting disc on a die grinder or moto tool and grind it away.
This? Window screw broken off.
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Old 07-13-2013, 07:15 PM   #5
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Thanks for all the responses....and I am eventually working through all the ideas until something works. I'm also trying to track down some cannilbalized frame components and am waiting to hear from my connection.

I thought I was up on all the different fasteners used in manufacturing because of the nature of my work. I've seen cheesehead, filister, tri-wing and British Standard Whitworth, but I've never seen a Robertson machine screw like this before!

WARNING: Canadian Content ahead....
BTW, while checking the Robertson website, I've discovered the existence of an #00! Used for #1 or 2 screws and has an orange handle

I will keep you advised....
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Old 07-18-2013, 05:42 AM   #6
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Update:

I ended up using a cut-off disc on my trusty 30+ year old Dremel tool (made the same year as our Boler, coincidentally). Just followed the slot and got almost all of it out and tried not to gouge out the aluminum itself. I did leave some of the original machine screw material and that worked great to secure the new screws installed during frame assembly.

Another Boler problem solved!

Thanks for all the advice.
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Old 07-23-2013, 09:18 AM   #7
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Originally Posted by Winfield456 View Post
Another Boler problem solved!
I love it when a plan comes together
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