How can I fix oversized hole?
 

The 2 holes which receive the 2 screws have been over tightened and therefore stretched open (if that’s the right term?).
Anyhow, now they won’t hold the screws. As you can see I have tried adding tubing over the screw to help provide some bite, but I would like a better more secure fix.
Any help/solutions would be appreciated. Thank you SmileWavy
http://forums.pelicanparts.com/uploa...1659124867.jpg
http://forums.pelicanparts.com/uploa...1659124867.jpg

Couldn’t you just use a bigger screw? Or if you can access the backside a small bolt and nut with a couple of washers?

A bigger screw would not seat into the recessed/tapered portion of the sunroof wind deflector; and it would just "look" wrong. There is no access to the underside to add a nut.

I don't think filling it with epoxy then drilling and tapping would work although I think Loctite makes such a product for this type application. Is it something you can pop rivet?

A few layers of fiberglass and resin in and over the hole should suffice. Once dry, drill the correct sized hole and ride off into the sunset.

Look up riv-nut or rivet-nut if you have room on the back side. There are inexpensive sets that contain a supply of various sizes.

Here's one. https://www.amazon.com/dp/B08MCVCWYL

Those riv-nuts sure look nice but I don’t have the depth to accommodate one. The fiberglass fill might be an option however.

I don’t weld, but could a welder fill the hole with something soft enough to drill and tap?

Old machinist trick is to place a ball bearing that is slightly larger than the hole on the hole and then tap with a hammer to stretch the metal towards the inside and tighten the hole up.

Welding sounds like overkill. You can drill and tap about any metal, though it looks like this is a sheet metal screw, which doesn't require a threaded hole, so drilling is all that is needed. Still, drilling and then beveling so the screw doesn't protrude could be tricky here with everything in the car. But heat is the issue - you don't want to melt or otherwise damage the upholstery. Were heat not an issue, you could solder, braze, or weld, and then redrill. Of course, you could peel back the headliner, etc., to get anything subject to heat damage out of the way. Want to get into that?

How is your fix holding up? But do you have anything to lose trying epoxy and fiberglass fill and so on? If careful with the application, have you anything to lose?

And just maybe there is a short sheet metal screw with a small enough head out there - these are doubtless metric. Maybe some SAE/Imperial sized screw is just a bit fatter in the shank? Thread type doesn't matter with sheet metal screws. You might even be able with a file or the like to modify a screws head enough to keep it low enough and out of the way?

Put a little dab of JBWeld in there. Then use a toothpick to make a hole small bit smaller than the screw. When it hardens use the original screw.

In these situations I put a bit of copper wire in the hole, then put the screw in.

Something like a U shaped centimetre (so it doesn't fall completely in) of wire stripped out from electrical wire.

I really like this idea: for some reason it rings a bell. Seems to me I read this somewhere before, long ago; probably here on Pelican:) Now I just need to find the right ball bearing.

And this sounds good too. I think I can combine these two ideas for good results.

Paper clips work well or as Bill suggested wire. Can’t find a ball bearing a center punch will work if you have the right size.
Last resort jb weld putty or 3m panel adhesive

Maybe drill another hole an inch away, dimple it and put a black plastic plug in the old hole.

+1 on the JB weld suggestion. Fill in hole, then after 24 hours or more. Redrill

Over size hole
 

Per the "KISS" rule of thumb, I would simply use an oversized washer that fits the screw and is larger than the hole.