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Originally Posted by monocoque
I know what you mean about the possibility of breaking off an ez-out. I've done that before. The ez out would be very small in this case and thus easy to break. And these screws are "welded" in tight. So I've got to be very careful, using the percussion and drilling techniques, or maybe, as you suggest, I polish off the grinding a bit more and let the sleeping screw-dog lie... I'll try smaller drill bits. You can see the drilling tending to wander over into the aluminum a bit in one of the photos before I decided to stop.
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I used a dremmel tool cutoff to cut the slot in the screw down until I was into the shaft of the screw, with caution not to go too deep. A simple twist of the screwdriver would break off half the screw head. I would then use the dremmel and cut the second half of the screw head off. Very little is left holding it on. It takes a little caution, but with a hundred or so screws, you get the practice and quickly develop the skill.