screws

I am trying to spruce up a set of 29 smoothbores for sale, and I want to replace all the old rubber since they have been sitting on a shelf for a really long time. I started disassembly, and ran into my first challenge with the screws that hold the bodies to the bracket. When I realized a screwdriver was not going to do it, I pulled out my trusty impact tool. As soon as I saw it was starting to deform the slots, I stopped. I am now in the middle of a few days of Liquid Wrench therapy, (the screws, not me)  which will culminate in a heat treatment and another try.
If somebody has a better trick, I'd be wiling to try it.

Also, does any body know of a source of replacement screws for this? They seem to be yellow cad plated. I hope not to have to destroy any, but I would like to be able to replace one or two if needed.

P.S. I ain't touchin' the jet block.

Vessel Impacta #3 works great on those screws.  I've banged out hundreds of them without damage.  Sorry, but I don't know of a good screw replacement source.  Please share if you find one.

Here, but it’s looking like the replacement OEM are not yellow chromate. If you buy them talk to Nessism he might dip them for you. Yellow chromate is just a color dip added after zinc.

Kawasaki 221B0614

www.partzilla.com/product/suzuki/09126-0...612ca2e81f17f867adad

Thanks. Even cheaper from Webike

japan.webike.net/ps/09126-06007/#!search&p.k=09126-06007

Yet another option. Honda 93600-06014-oh. Same head size/taper and JIS #3, 6x14mm. Actually used on a lot of cars too, brake rotors. 

McMaster-Carr has them in zinc.

www.mcmaster.com/products/screws/thread-...el-flat-head-screws/

Welp, patience, more penetrant and some more violence with the impact did the trick wit no more drama. One good whack each got them loose.

 

Now my dilemma is, do I replace the one damaged screw with a stainless or zinc screw, knowing it will stick out like a sore thumb, or do I replace all four, omitting seven perfectly useable originals?

My inclination is to do all of them.

If you are going to this much trouble do them all, keeps it looking uniform 

Hmmmm. Partzilla shows the Honda version as available and it looks a little yellowish. Part number ends in 0A, wonder if 0H superseded it?

www.partzilla.com/product/honda/93600-06...76951227aab05013843c

The two sets I can find on fleabay do not have the yellow screws and neither set has been cleaned or rebuilt, so I think I should be ok with some shiny stainless or zinc screws there. On set has a plastic cover on the choke lever and plastic floats. Were those later production changes?