Screws rusted on defender door handle and can't remove?!

Hi all I am trying to remove my passenger door handle on a 1989 defender 90
I am having a bit of difficulty removing the screws as they have corroded and the heads are rounded off, can you drill the old screws out?

Hope someone can help!

yep its a peice of cake mate, just use a decent drill (no poundland specials or you will just make hard work for yourself)

drill the heads off and the door will pop off, so be careful and have someone hold the door when doing it.

afterwards you can just tap the old j nuts off with the studs still in them and they will fall through the chassis onto the floor

10 minute job.

next time use an impact driver and most of the time they will free off corroded screws before they round off.

and when you fit new bolts, put some copper slip or other anti seize paste (i use this non setting plastic stuff but the name eludes me at the minute)

"drill the heads off and the door will pop off, so be careful and have someone hold the door when doing it."

Certainly the case with the door when replacing the hinges (although closing the door means this won't happen unless both hinges are replaced at the same time) but he spoke of door handle.

oh yeah, i werent paying attention. distracted by the fab lolly in my hand

I used a grinder from the outside on mine

cheers for the replies am also going to tackle the job of replacing the hinges as they are on their last legs!

Hello mate I had the same problem on mine last week I just used a dremel with a grinding head on. Went through in no time

I did my hinges too. I would 100% recommend using an impact driver. I didn't have one and the only option for me was to drill the heads off with a beasty drill bit.

defender79 said:

Hi all I am trying to remove my passenger door handle on a 1989 defender 90
I am having a bit of difficulty removing the screws as they have corroded and the heads are rounded off, can you drill the old screws out?

Hope someone can help!

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Go on, be a devil and have a go.