ORIGINAL: Gray Beard
Yes I did and the hammer wasn't all that small!!! I used to be an engine builder for an after market VW company and at one point I had a set of tools for removing stuck hex head screws, sort of like easy outs but these worked. They seem to have grown legs sometime over the years and walked away. I have a machinest in my wood working club and as much as it pains me to give the engine to him to remove these nasty screws I will just have to lower myself. I have one more trick to try before I give up though. I have had this engine apart once and I never use locktite so I question how these screws got so tight in there. I know I cleaned all the threads on both screw and hole plus I torqued them all the same with an inch pound wrench. One shouldn't be any tighter then any other??? This is a first time for me having this problem with an old engine???
Gene, try an old trick that I picked up on my apprrenticeship back in the 60's. First grind the tip on your allen wrench flat, giving the end to side a sharp angle, not the rounded ones normally on hte wrench, make sure it square, If t he wrench is shinny from use, grind it down past the shinny part to give a new surface to work with. Make sure you keep the wrench cool when grinding so you don't upset the temper. Don't clean the sharp edge and leave the pull over from grinding.
Now, put the wrench in the screw head and gently tap it a couple times to make sure it's seated. Use an cressent wrench tightend to the allen wrench and place it on the L and use it for a handle and not the wrench handle.. A piece of thick steel tubiing will work also, you want to take a much spring out of the wrench as possible. This all gives you the best leverage on the screw. NOW tighten the screw. Just enought to feel it move, then unscrew it. If this doesn' work, find a machine shop with a wire EDM machine and see if you can talk them into buring them out for you.
Don