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Both of the stainless cap screws holding the rear carry handle of my PA12 have broken off at the head. One broke while picking up the kayak, and the other snapped when I tried to unscrew it. Looks like a corrosion cracking issue after years of saltwater exposure.
I made an initial attempt with the standard methods of removing a stuck bolt stub (cut a slot to use screwdriver, drill a hole to use a screw extractor, soak w/penetrating oil, heat/cool cycles, etc) but they're completely frozen in the brass inserts.
I'll keep trying to get the screw stubs out, but I'm not hopeful. So if I can't get the old screws out of the inserts, how to proceed?
-Is it possible to heat up/melt out, extract, and replace the inserts? (seems like that would be very tricky and risky but might be possible?)
-cut/drill out the whole insert and replace with backer washer and locknut? (would leave about a 1/2" hole I think, also not a very accessible area to work, but seems feasible)
-give up on the old mounting holes and remount the handle in a different position? (not desireable)
Any other ideas? Mahalo!
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