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All good ideas, but first try this little trick, which has never failed me for removing stubborn or delicate screws...

Chuck-up the appropriate sized allen bit into your reversible drill-driver nice and tight. Set the clutch to one of the lowest settings, insert into screw and run in reverse direction. The clutch will slip and act like an impact wrench on the screw. Step up to a higher setting or two on the clutch and continue to do this. It will come out in a minute or two.

Oh, and don't forget that the best penetrating oil for frozen bolts is a mixture of 50% ATF and 50% Acetone.

Best Regards!
Garth
Success - finally. I tried most of these ideas, except the drift punch, with no luck. I didn't have a 5 mm impact drive bit or any acetone, so I got them. Another day of soaking with the acetone / atf mix, then used the hammer drive impact; still no go. I think the metal underneath flexes too much. Then I put the 5 mm bit on my air drive impact wrench, and that did the trick.
As I suspected, the threads were never the problem. The problem was galling in the countersink area.
Thanks for the tips, I'm sure I'll use them again. Rodney
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