Modern Vespa

The securing nuts for the top of my headset are frozen and I need to replace the headlight. Before I get out the drill and EZout the things is there anything I should be wary of inside the headset? I've never worked with a two-piece unit before.

You could try tapping a screw driver into the heads of the screws with a small hammer. Sometimes vibration will loosen stuck screws. Also, try driving the screws first clockwise and then back out, and then in and out as you work them out until they turn freely. A small cordless impact drive or even a hand-held driver might also free them up if you are careful. Use the right size screw driver.

I have exhausted all alternatives...heat, penetrating oil, PB blaster. I suspect this is an old problem because one of the screws slots is completely round. It appears someone else tried and gave up one day.

I may give the others a try with my manual impact wrench. By the way, everyone should have one of those... Craftsman makes it.

How do you get PB Blaster into the right places without the scooter upside down? (+:

I have had luck in the past making a lever to increase rotational force on the screwdriver. The lever is simply a quality vise grip, locked and oriented in the correct "strong" way on the handle of the screwdriver. Using one hand to exert maximum pressure on the screw head, I use the other hand on the vise grip to turn the screwdriver.

I know it sounds unbelievable, but this has actually worked to get me out of very similar situations.

Just drill the heads off the screws with a bit the size of the screw shank. 3/16" ?
Then you can take the top off and remove the studs with PB, heat, and vice grips.