[wetdog]

Baz, in the aircraft industry this happens to the best of us !!! sometimes it is in a part costing hundreds of thousands of dollars EDM is the least destructive and going down the list to a carbide burr on a high speed grinder ..with patience it will eat it up and if not perhaps you can eat the surrounding metal enough to move it or punch it through . I do not have much faith in the tap removers especially after you tried hitting it through. Baz I have used the cabide burr with much success and it is very cost effective feel free to PM me if you need more info ...WD