I'm not sure I understand the problem since it sounded like you have blinds that are bigger than the window frame, except they fit in anyway somehow; but; there are probably two approaches, although the first is likely out because the holes may already be drilled. Smaller diameter screws will have smaller diameter heads. Of course they also wouldn't hold as well as the larger ones. The second approach is to drill out the holes in the bracket with a large drill bit much bigger than the current bracket holes. You drill part way thru so that the screw head fits into the taper of the newly drilled tapered holes. If the bracket is very thin metal, you would just use a slightly bigger drill bit to slightly enlarge the holes, but unfortunately, then there is minimal surface to retain the bracket and the first (smaller screw) approach would probably be better.

a picture would help.

Thanks, chas045. My husband mentioned both those things this evening. He thinks if he makes the hole slightly larger, the screw head would seat farther into it just enough to allow the header to slide in.

If it weren't for the screw heads, the header with the brackets fit inside the window frame with barely ⅛" clearance on the sides, which unfortunately, with the screws on both sides of the header need just a smidgen over that (like 1/32 to maybe 1/16).

I've not tried adding photos to Garden web in years, much less since it became Houzz. I'll try later.

Thanks for the replies!

Tracey

Adding photos is pretty easy. When you click on the box that says "write a comment", the box expands and adds options below the box. Click on the Photo button and another pop up box will appear asking for the location of the photo you want to post. Then you double click the photos name and it will appear in the reply box you are working on. (That's how it works in Windows anyway).

Don't just make the holes larger, countersink them, using a countersink bit and making sure you use flat head screws.

I don't see how that will work randy if she's putting a screw through a hole in a stamped metal bracket into the wood. Countersinking it will give it nothing to hold onto. You could try a nail, they have very flat thin heads...

I didn't see that hers were metal. If so - "never mind".

I assumed that the 'brackets' installed inside the window frame were some type of metal bracket. We're at a disadvantage without pics.

Thanks for the replies.

Here's the "screw height"--it's approx. 1/16th; that times 2 sides and it's just a smidgen past the ⅛" allowance in width. My husband hasn't had time yet to mess with it, but is planning on using his drill press to expand the holes just a tiny bit so the screws can sit ever-so-slightly lower which will allow the blind headers to slide into place.

Should work, right? :-)

Use a smaller diameter screw of same length. That looks like a #8, Try a #6. I almost hate to mention this, but a drywall screw's bugle head might also get you the clearance you need.

Or, a pan-head screw instead of a countersunk.