Drilling Bodywork

[Mr. Flibble]

I now have a whole bunch of Mods on hand that I need to install in my Delica. (the Frantz filters just arrived).

Frantz Filters, IC Sprayer, Snorkel...

Each of these will involve drilling holes in the bodywork. Previously, with my 4Runner, I did not really care much about rust issues etc, so, when I needed to drill something into the bodywork or frame, I just did it. However, I now have a much nicer vehicle, and I don't want to promote rust! So, what would be the accepted procedure for drilling bolts and holes into bodywork in a manner so as best to avoid the dreaded rust Demons?

[FalcoColumbarius]

Drill an oversided hole; paint hole (NOT latex or any water borne coating) ~ let dry; install rubber grommet if it's a cable or pipe you are pushing through. If you are going to screw or bolt to it then I would suggest at least painting it. You could coat it with oil but that will dry up eventually.

Falco

[Mr. Flibble]

Drill an oversided hole; paint hole (NOT latex or any water borne coating) ~ let dry; install rubber grommet if it's a cable or pipe you are pushing through. If you are going to screw or bolt to it then I would suggest at least painting it. You could coat it with oil but that will dry up eventually.

Falco

Hey, thanks! That is great advice! Any advice for self-tapping screws? Or, should I just not use them at all?

[Firesong]

Or if you are really concerned.
Drill hole, coat hole and inside with POR-15 and smile.
No Rust going to happen there.

FS

[Artacoma]

Avoid self tappers and if bolting on something with a flange use a gasketing material like Sikaflex. Also use sharp bits that drill quickly so the paint around the hole doesn't get cooked.

[deLOOKA]

Friend had a power sunroof installed on his Pathfinder. And another one had holes drilled for his roof rack system.

Falco? Firesong? Think the same method?

Never really thought about it till now. Good question.

[pajerry]

Avoid self tappers and if bolting on something with a flange use a gasketing material like Sikaflex. Also use sharp bits that drill quickly so the paint around the hole doesn't get cooked.

Avoid self tappers eh?

In the SWB Pajero, one of my only options for a rack system is self taping either landing pads, or rails right to roof. Any thoughts on this?

Also, if you lay down strong masking tape where you're drilling, it can help prevent paint chipping on the edges of the hole, so I've heard.

[FalcoColumbarius]

Laying down tape can be good, especially for drawing out your pattern ~ but I have to agree with Artacoma about drilling with sharp bits so you go through faster and spend less time heating the metal surface with continuous friction from a blunt bit and less chipping.

Falco.

[Artacoma]

If you can't avoid self tappers then drive the screw , back it out , put in a squirt of sealant and redrive the screw,

[EnviroImports.com]

In the SWB Pajero, one of my only options for a rack system is self taping either landing pads, or rails right to roof. Any thoughts on this?


There are other options for the SWB Pajero, the screw at the back comes off just inside the rear door and you can get a rail to go inside the track,
not easy, but alot better than drilling holes in your roof....