Frozen screw in aluminum window frame

Can you share a photo?

Thanks for the photos. I assume there isn't enough of the stub to use needle nose vise gripes?


Drilling it out is a possibility but you'd have to with a very small bit and have a steady hand to avoid destroying the threaded (soft) aluminum hole.

From the picture it looks like the screw can be removed from the backside. Instead of trying to remove the screw out the front try to continue screwing it inward and then remove from the back. That channel space should be big enough to allow the screw to come out. That screw was originally screwed in. Continue to screw it in and see if you can get it out as long as the shoulder of the screw doesn't bind. 

Work from the front in and out to free it. Use a penetrating spray to help and keep it coated as you work it back and forth.
Take your time and don't force it. 

I would use penetrating oil like stated above, it comes in a spray can and most autoparts stores have it. You can also try WD-40 in a pinch but it doesnt penatrate and loosen as well as penetrating oil does.

Like Jukebox said and turn it out the back side, then you wont be trying to grind the extra corrosion into the treads.

If you can safely apply heat without catching the camper on fire, heat the bolt up before spraying with penetrating oil. The heat/cool cycle will expand & contract the metal which can help break it loose, plus it will draw the oil in deeper as it cools when the oil is applied kind of like the way solder sucks into a joint.

I am going to go along with nccamper's suggestion, but I use a regular 4-inch vice grip pliers. The trick is getting ahold of the screw body as tightly as possible the first time, before trying to twist. The needle-nosed version always twist enough to snap off the screw when I have used them. I have had very few screws, including the ones where dissimilar metals are at work, that would not give up to the vice grips.