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Seized Screws - Impact driver fail

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StPeter:
 >:(
Removed the alternator cover this evening - well tried to! Yes, I've got my trusty impact driver but the lower two screws had obviously experienced previous abuse and there wasn't much left of the heads. These two aren't blind so the back end will be exposed to all manner of damp crap to aid electrolyitic corrosion. Quickly got to the drill-the-head-off point (man, those screws are harder than I remember).Cover off, two studs exposed. The mole grip will get them now that the tension is removed . . . . see, I've done it before. Unfortunately, not on a 37 year old. Got the back one out but the front one refused to move and the inevitable happened - it snapped off with about 8mm sticking out.
I think I know the answer - drill out and helicoil (if there's enough meat there) but has anyone got any other suggestions?

kifer:
When removing cross heads that have been abused I usually tap lightly with small hammer then tap a torx into them very slight tighten then undo seems to work more often than not.  As for broken ones fit a nut on top and mig centre then use spanner.
These are what work for me but expect there are loads more ways, Good luck if you struggle go have a brew come back when cooled down  :) Tom.

LesterPiglet:
I have in the past drilled broken screws out with a slightly smaller drill, then chipped away at the remainder with a hammer and a scribelike chisel, (something I knocked up with an angle grinder) and managed to save the threads. I think the heat from the drill helped break the corrosion a bit.

StPeter:
Good thoughts, guys. Especially the thermal control effect of a brew! Unlike when I used to do this stuff before, I don't have to get it running to get to work in the morning. I'm doing it for fun. Remind me again how much I'm having!

Bryanj:
Blowtorch of the type that plumbers use with disposable gas canister, warm up the alloy and douse liberaly with WD40 or similar.

ALWAYS hit the impact bit into the screw head before attaching the driver and trying to undo and remember that they ARE NOT pozidrive( and not exactly Phillips either)

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