Morris Minor Owners Club

The two self-tapping wood screws that hold the traveller back door handle on had rusted badly, and the heads sheared off when I attempted to unscrew them. Any ideas how I can get the remains out without damaging the wood too badly so that I can fit new screws in their place?

Are the screws sheared off flush or below the surface of the wood??

I do have an idea.

1) Remove door from car,
2) remove ali panel,
3) (with rags to protect surface) clamp door securely near to where the screws are under a pillar drill.
4) carefully use pillar drill to drill out the remains of the old screws (with a bit the right size for replacement screws).

Dip new screws in waxoyl before fitting.

I have never tried this but it is the only way I can think of drilling out the rusty screws without the drill bit slipping off and drilling into the wood instead.

Or you could bodge it by drilling new holes right next to the old rusty ones.

An end mill cutter might be better than a standard drill bit in the pillar drill and a dowel glued in to plug the hole.
Just an idea as the cutter will not tend to wander like a drill bit.
Regards

Soak with oil - then grab the broken end with vice grips, and twist ?