how to drill out ignition switch screw on gt

[ckeen74]

Hi all,

I was trying to replace my ignition switch last night, and of course there's the screw with a broken-off head in there. Even though I undid the rake-adjustment mechanism and removed the upper shroud to give myself a bit more space for the drill, I still can only drill at a really awkward angle. Haynes only says to remove the lower shroud and drill out the screw. How have you all gone about replacing one of these? Also, any idea what the screw's dimensions are?

This car is bound for a road trip to Seattle/Vancouver next month, so any replies would be appreciated - I really don't want to have to drive the Golf.

Thanks!

[okiealfaaddict]

I used a dremel tool to cut a slot across the screw head and used a regular flat tip screwdriver with a wide blade to undo the screw.

[ckeen74]

Thanks for the tip - unfortunately, I don't have a dremel (I know, weird, considering I have an Alfetta). I think I'd go to my mechanic before I resort to buying new tools I wouldn't use frequently.... has anybody been successful using other methods?

[ossodiseppia]

Quote:

Originally Posted by ckeen74 Thanks for the tip - unfortunately, I don't have a dremel (I know, weird, considering I have an Alfetta). I think I'd go to my mechanic before I resort to buying new tools I wouldn't use frequently.... has anybody been successful using other methods?

[papajam]

Another way is to use a sharp pin punch. Place the punch on the bolt such that when tapped with a hammer, the bolt will turn counterclockwise.

[sh0rtlife]

a hacksaw or sawzall blade in you hand or a punch.....dremel makes it easy!!

its not that hard to pull the column or atleast drop it down so its easyer to work with..just pull the adjuster bolt

[okiealfaaddict]

Bite the bullet and get a (generic) dremel kit. You will be surprised at how often you will use it.

Harbor Freight Tools - Quality Tools at the Lowest Prices

I doubt $7.49 will break the bank!!!!

[okiealfaaddict]

Actually, come to think of it. Before the dermel tool, I used a broken hacksaw blade with a rag handle to cut the slot. There is really no reason to get a drill involved.

[sh0rtlife]

Quote:

Originally Posted by okiealfaaddict Actually, come to think of it. Before the dermel tool, I used a broken hacksaw blade with a rag handle to cut the slot. There is really no reason to get a drill involved.

[festy]

It's really easy with a punch, you don't need to go cutting slots or anything.

[ckeen74]

Didn't realize dremels were that cheap, 7.49 sure won't break the bank.

I *am* curious about this punch method, however. How does using a punch make the screw come out? Even though nobody will ever look under the shroud, I'd rather avoid cutting anything if possible.

[steve11]

What does the punch look like? (any Photos?) Where do you get them and how much?

Thank, Steve

[Craig]

Use a center punch on the outer edge of the dome of the bolt at a tangent to drive the bolt anti clockwise (ie. undo).

[festy]

Sorry - it's a center punch, purchased from any hardware shop for a dollar or two, or easilly made for this job.
See Punch (engineering) - Wikipedia, the free encyclopedia

[ckeen74]

Got it! Okay, I'll try that tonight, wish me luck.

Any idea on the size of the screw? If not, I guess I'll just take the replacement (used) switch to the hardware store and ask them to help.

Thanks!