SNIP
Make the galvanized plate from aluminum, big
reduction in problem. Make the screw aluminum as well, problem gone (but
you'll need to be sure that the aluminum plate and the aluminum screws
are designed in sizes that will do the job, if that is possible.)

That's part of the problem. The plate needs to be real stiff so aliminum
won't work. As it is, UPS Ground sometimes mangles them in shipment which
always amazes me!

As for the screw... I could try to find galv. screws but aluminum surely
won't work. Black oxide seems the best answer for all intents and
purposes... We need strength and most of the time, these things are there
for the life of the machine which could be 5 years and 10 million holes...
But if and when they need to be removed, they're a real headache. Not
nearly as bad as if one came loose or broke though and destroyed belts,
custom aluminum pulleys, guards, or worker's fingers!

Really what I'm looking for is an allen key-type tool that won't degrade
under stress like a full allen key will and/or one that I can apply either a
shock to (impact or something) or lots of torque to remove the flat head.

It's not a mjaor dilema, but I know how much everyone here loves to solve
problems like this so I figured I'd ask and try to learn.

Regards,
Joe Agro, Jr.
http://www.autodrill.com
http://www.multi-spindle-heads.com

V8013

My eBay: http://tinyurl.com/4hpnc