Removing Cap from 1978 23

[JW-Tex]

Previous owner used about 40 three inch deck screws (for use on wooden decks not boats) to hold the rub rail on. Every rusty screw head broke off leaving a fun little project to remove broken off screws from the hull. I will have good access to the back of the screws when I hoist the cap off. Any idea of the best way to remove these screws? Vice grips and go? If it breaks off from the back side I will have to try and drill out what is left. I thought about drilling very small holes around each screw to help it break loose if vice grips don't get them without breaking off.

I am open to any ideas? I could heat them with propane torch due to their length without hitting the glass if that would help.


Also the cap has a lot of gel coat stress cracks so I am planning on a couple of layers of 1708 on the underside to reinforce as well as new core material where applicable. Will the additional 1708 cause any problems when I reassemble (make the seam too large-stick out too far)?


Thanks

[deepsushi]

If you can get to the back of the screws AND there is some thread to get a bite on you could try a "titan stud extractor". The tool resembles a drill chuck that tightens down and bites into the screw and you can attach a ratchet.

[FLexpat]

Try this:
http://www.lowes.com/ProductDisplay?...llow&cId=PDIO1
I made my own without the diamond edge to get some broken screws out and ran it CCW so the screw stub backed out when I got deep enough. That worked ok - not having to make the bit seems a lot easier though.

About the 1708 - each layer of properly done 1708 is about 0.044" thick