Anyone drilled out a rusted stem before?

tallsam [quote]Mr Bungle Jake- the bolt's out and the wedge has dropped down so can't do that either..
Edmundane - It's definitely an "aluminium oxidising itself to steel" issue... no amount of coke or WD40's gonna do much i think..

This has worked for me before but could damage your headset (possible but not likely).

Place block of wood on floor and underneath steerer tube (between forks). Place block of wood over top of stem. Take large hammer. Beat the shit out of it like it was Gary Glitter and you were a 3 year old.

No bent forks, force of hammer blows may eventually loosen oxiding enough to twist stem. It worked for me.

No guarantees though.[/quote]

Sounds risky but possible - replace dangerous twisty force with only ever so slightly less dangerous mashing force...
HOT DAMN, I LIKE IT!