Removal of bolt from blind hole

[Tapitha]

I have a small bolt or screw with about a 3/8" across flats which is rusted into a blind hole. In spite of copious releasing fluid etc it obstinately refuses to unscrew. The head is now losing its flats and becoming rounded. Because of other bits in the way I can't use a stilson wrench or similar. In any case I am afraid of snapping the not very thick screw and being left with a broken piece in the hole. The screw is the small one holding a Wolseley front brake cylinder to the backplate, everything else has come undone OK, although with effort!
Any ideas please on how I should proceed, or would it be best if I left it alone and reconditioned the cylinder in situ which I could do?
Mike

[bmcecosse]

Leave alone if you can......but you can also simply gently drill the head off, and then drill and tap the remains once you have the cylinder on the bench. It's 1/4" UNF thread. Cap screws work well here - smeared with grease when fitted to fill the 'cap' and stop it rusting away.....

[mike.perry]

You have various options. File the head off to remove the bolt. I might have some W cylinders, condition unknown. Convert to M1000 cyilnders

[Alec]

Hello Mike,

"File the head off to remove the bolt."

Do you have a lot of spare time, that's the most laborious way to remove a bolt head?

Alec

[bmcecosse]

And there is no room to move the file........ Drill it!

[Tapitha]

Thank you for your help. I have decided to leave it alone as I don't want to spend ages trying to drill etc and then possibly fail. Shame because I wanted to strip everything down but I can still complete refurbishment of the Wolseley brakes. Funny how it is always the last to screw up or unscrew that gives trouble. Must be somebody's Law!
Mike

[mike.perry]

If you want any W cylinders I will see what I have but long term I would fit M1000 cylinders as they are going to be more readily available in the future