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Thank you for the reminder. Yes, I have done that but it's not what's going on here. My dad even tried with his super slow-speed drill really leaning on it, too, with no luck.
Try PB Blaster Penetrating Catalyst rather than WD-40. Then, try applying some concentrated heat to the screw shank using a pencil-type soldering iron. Careful... alternate heat on - heat off, using your judgement as to duration so as not to damage surrounding materials. Re-apply a drop of the PB Blaster after a few heating/cooling cycles.
You mentioned cutting off the screw head with your Dremel. Is the shank flush with the surrounding surface, or is it protruding at all? If protruding, and there isn't enough shank to grab with a Vise-Grip, try cutting a narrow slot with the Dremel to enable you to use a thin blade screwdriver to apply some torque after several heating/cooling cycles.
Good luck.
Louis
PS - Pursuing the drilling option, another source for end mills and micro drills is www.cetdirect.com
Unfortunately, the screw is now cut off flush, so there's nothing to grab with pliars. Good idea about cutting a notch a screwdriver could get in. Yes, I have some PB Blaster-great stuff! Well, those carbide bits arrived today, so I'm very curious to try them. I'll report how it goes.
Well, I tried the carbide bit. Boy, did it work! It immediately began cutting big, long slivers of metal, and that's when the cobalt wouldn't even touch it. I used my slow, torquey drill (800 rpm max.) at less than half-speed and proceeded cautiously. It cut beautifully. I guess I've learned what carbide bits are for!
By the way, I ordered them from Drill Bit City on the 'net. They had new carbides, or resharpened carbide bits for half the price of new. I got resharpened bits, and they worked great. The only thing to be aware of is the bits I got from them are only around 1.25" long, which worked great for that little screw, but a larger task may require a longer bit.
I'm still very curious how a screw can be so ridiculously hard as to require a carbide bit, yet the phillips head strips easily with merely a screwdriver?!?
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