Do it right? Juryrig it? Or f#@% it?

ABS isn't functioning on my minivan ('06 Chrysler Town and Country - serves mostly as winter beater and occasional keg hauler). Appears to have been buildup of corrosion on the metal teeth of the wheel which has worn up against the sensors. I have scraped off as much corrosion as I feel I can, and am in the process of replacing the ABS sensors. This is where the problem comes in:

The sensors are held in place with a plastic spike and *one* bolt, and that bolt has sheered off on both sides. I attempted to drill a pilot hole and use a screw extractor, and snapped the end off the extractor.

The little metal spike holds the sensor in place surprisingly snuggly, but I'm sure would back out in time on its own. So trying to decide how to address this issue.

Do I:
Try to do it right - get a nicer drill than I have, remove the brake rotor, and attempt to drill the bolt out from its back side in the steering knuckle. (This *will* be a PITA, and may not even work.)

Attempt to juryrig it - I could potentially use some gasket maker or epoxy to try to hold it in place. If something happens, it then wouldn't be too tough to scrap the gasket off.

berkeley it - Just stick it in there with the plastic spike. If it falls out, it falls out. Or take the sensor off for now to save it for if I do feel like I've got the time and energy to repair it properly later so I don't risk damaging these new sensors.

Nothing is more permanent than a temporary fix that keeps working.

Since shotgun seems unlikely to work, how about zip ties?

Honestly, I would go with your middle option.  I think you need something to secure it a little because as a winter beater it will likely be hit with slush while driving. 
 

I learned long ago that doing things half assed means I'll have to do it at least twice, and more likely three times, whereas if you do things whole assed you only have to do it once.

So 2x(ass/2) = ass, or 3x(ass/2) = 1.5ass

And 1x(ass) = ass

Might as well do it whole assed once.

Shove it in all the way and RTV it?

also, long time no post! I hope the beer baroning is going well!

Mr_Asa said:

I learned long ago that doing things half assed means I'll have to do it at least twice, and more likely three times, whereas if you do things whole assed you only have to do it once.

So 2x(ass/2) = ass, or 3x(ass/2) = 1.5ass

And 1x(ass) = ass

Might as well do it whole assed once.

Mr_Asa's ass is correct. And a failure in winter could get one's ass in deep schist. Save your ass before you end up looking like an . . . ass. 

Duke said:

Since shotgun seems unlikely to work, how about zip ties?

Honestly, I would go with your middle option.  I think you need something to secure it a little because as a winter beater it will likely be hit with slush while driving. 
 

I wish a ziptie were an option. Unfortunately the only hole to loop it through has a sheered off bolt in it. 

I ended up going with epoxy.

AngryCorvair (Forum Supporter) said:

Shove it in all the way and RTV it?

 

also, long time no post! I hope the beer baroning is going well!

That's pretty much what I settled on. Only Epoxy instead of RTV. As suggested by a friend who is a Honda master mechanic.

This is a hell of a time to be beer baroning. The Covid advisories are really rough on the taproom. I'm technically furloughed for a while.

In the broader sense, they're actually doing pretty well for us. We are now the first Brewery-AND-Distillery in central Ohio. Have Vodka, Rum, and two Gins out. We've got Bourbon ready, but are waiting for gov't approval to be able to release that. Same deal with a malt whiskey (like Scotch), but that was a small run that will be for the bar only.

In reply to Beer Baron :

Do you ship for in-store sales?

I've got one of these zip tied/pressure fit on an NB Miata now. The original bolt and sensor both broke off. Drilled/ez-outed them out and had to hammer the new one in to actually get it to fit. Unfortunately it shifted like an eighth of an inch off the bolt hole in the process so snug up a zip tie as tight as it'll go and called it good.

Hope the beering gets you back in business soon.

I agree with the epoxy thing but i had a sneaking suspicion such a part would be dirt cheap, and turns out they are. You can buy a used spindle from a southern junkyard for $33.