I agree. I'd say it's going to be one of those jobs where the only way to move ahead is to just back up, slow down, and admit there's no way out without a lot of tedious work - and just do it.
Grind it. slowly and accurately with a die grinder or dremel tool.
You usually find it takes less time to do it than it does to try to figure out a better alternative.
Try your best to keep the whole in good enough shape to re-tap.
You can always go heli-coil if need be, but consider that as a last resort while you work.
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Today's Featured Article - A 1937 John Deere Unstuck - by Gary Hickman. Here is my story of how I got the pistons out of a 1937 JD B that the engine had been stuck for about 14 years: About 12 years ago my Dad gave me one of the tractors I ran as I was growing up on our farm in central Nebraska. The engine on this tractor, a 1937 John Deere "B", had been stuck for 2 years before he gave it to me. This last spring (1999) I hauled the tractor to our 2 acre lot in St. Libory Nebraska where it joined my antique machinery collection, at that time a 1929 Caterpillar T
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