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Definitely one of the most frustrating parts of my build thus far. I generally regard my spacial orientation as pretty solid, but this bending and twisting of the posts got the best of me. I'm glad that I got the Whitby SS inserts and I totally would have stripped the stock brass ones long ago. The issue I had was that I was able to get the bottom 3 screws in place, but there would be a slight gap at the top and the top screw wasn't long enough to reach the threaded insert. If I put the top screw in first, then the bottom 3 would be slightly off. I tried opening up the top hole a bit but because of the chamfered edge of the post, it kept pulling the top screw into the same position. I tried opening up the chamfer but didn't want to strip away any more chrome than necessary. Getting a longer screw was an option but I didn't want to risk having a longer screw touch the glass/grommet leading to a crack. I finally decided on putting a stud (longer screw w/ head cut off, slotted w/ a dremel for a flat head screwdriver) in the top screw hole on both sides with an acorn nut on the end. IMO it doesn't look too out of place. It also helps a lot when replacing the posts. I just hook the top hole on the stud and then attach the bottom screw loosely and then attach the other ones.
I also drilled and tapped the windshield posts w/ a 1/2"-13 tap. I marked the holes with the WS 27" from the top screw hole to the front lip of the door opening, then transfered the location to the center line of the post. Man, drilling that hole was a violent event. bits of brass thrown about with several arm-jerking events that almost ripped my shoulder out of its socket. I had to open up the body holes a bit with the posts sitting a bit diagonally to the original slotted holes.
I also drilled and tapped the windshield posts w/ a 1/2"-13 tap. I marked the holes with the WS 27" from the top screw hole to the front lip of the door opening, then transfered the location to the center line of the post. Man, drilling that hole was a violent event. bits of brass thrown about with several arm-jerking events that almost ripped my shoulder out of its socket. I had to open up the body holes a bit with the posts sitting a bit diagonally to the original slotted holes.
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