Drilling screw in 91 sl panel removal
 

I am having a door lock problem after a new lock actuator was installed by a local shop. I am attemping to remove the panel to check the vacuum line. When I removed the front pocket screw I found a very large machine screw that was very hard to remove. The back screw was stripped, ie, it would turn but not unscrew out or in. I tried a lever to push the panel against the screw to no avail. This back screw is buried in the panel plastic about 1.5 in.
Then I attempted to drill out the screw head. I have used bosch titanium drills and a home depot colbalt drill. These bit are not able to drill through this head. I have a little progress but it is not progressing.
Any ideas on how to procede? Thanks in advance for any ideas.

If you just paid to have it installed, why are you working on it ?

What size drill bit are you using? Start with a stubby 1/8" diameter to get a pilot hole going.

take it back to the shop. You should check the work order for warranty. If you tamper with it, it might void your warranty.

not so smart move
 

You are right. I got delayed with an upholstery and carpet job on my porsche. The top is still out. I was trying to determine the status of my vacuum pump before taking it back to the shop. Too many $1000 shop bills.
I should not have started drilling. I am going to try a smaller drill however i need length to keep the drill out of the panel upholstery.

OK, use a high sped drill ( 1,200 RPM would be good ) and don't push too hard as a long bit will break. Also, don't let things get too hot as it will melt plastic.

For max speeds see this chart.
www.imperialsupplies.com/pdf/I_Drill-Bit_PRMChart.pdf

making progress
 

I took your advice on starting with a smaller drill size. The bosch titanium bits were not tough enough. I bought some dewalt cobalt drill bits today and I think I have gone through the head. I will pull the panel tomarrow to see what kind of mess I have to clean up. more later.