RE: Mcguyver Jackson
Hi wsurfn (Mark,....right?):
o2bnme (Bill) has it right.
Best way is to find a drill press and clamp the boom head down snugly
to the drill press table (or hold it lightly in a vice attached to the drill press table.
Use a cut off allen wrench (the size that stripped out) as a centering device.
Then select a drill slightly larger than the diameter of the screw (not the screw head) and carefully drill down through the head of the SS (CRES) alllen screws until the head separates from the threaded body of the screw.
Take a small drift pin and punch the remaining threaded portion of the screw out of the hole in the boom head.
I've done several of them this way.
You can do them with a hand held drill motor (either plug in or cordless) but you get a much better job and better centering with the drill press.
To avoid this problem in the future, buy a can of "Never-Seize" anti-seize compound and put a small dab in the holes before you reinstall new screws (which you can get from Dave Dominy at Streamlined).
The Never-Seize will prevent galvanic corrosion from causing the white aluminum oxides that have caused you problems here.
8 oz. brush top Never-Seize can be obtained under the Part Number
NSBT-8. Most bearing supply stores either have it in stock or can order it for you. (Kaman Bearing/Motion Industries... and similar industrial supply warehouses).
Hope this helps,