We have a Simpson Lawrence 555 "Sea Tiger" windlass which is in
need of some basic service. It seems that the key to removing the
gypsy (so that the clutch can be cleaned and re-greased) is to
remove the chain stripper. In order to remove the stripper, one
first needs to remove the set screw which (on our windlass) is
not only frozen, but sheared off flush with the base of the windlass.

Being a good little net user, I've googled the rec.boats*
newsgroups and found all manner of really unpleasant techniques
for removing frozen steel bolts from aluminum objects. We've been
gradually moving up the ladder of suggested drastic-ness, but
before we do anything that might damage the housing, I was
wondering if there was anyone out there who may have done this
specific screw removal project and who might share how he did it.

Also, how bad would it be if we just cut off the stripper and
tried living without it?

Thanks

Cindy