Some times you can take a punch and a hammer give the a couple of sharp hits to loosen them then carefully take a Dremel tool and cut a screwdriver notch that will let you take them out. Doesn't always work but sometimes it does. Might be worth a try. Then if need be drill the hole out larger and glue in a hardwood plug to hold the new screws. You also could take a small hole saw and cut the screw out then plug that hole, If you do that make sure you seal the area before installing new wings. Let us know what you do.
Good suggestions. I was going to suggest moving the mounting by the width of the screw or so, just enough to miss the old ones, but you still would have to seal off the spots where the old screws had pierced the aluminum.
I have not bought from Tyler yet, but I do intend to. What most people see is a set of repro wings that are pretty and fairly expensive. What they do not know is what he had done to make them the way he does. A couple years ago he did a lot of research on the old forum. He had people sending sample wings to him (which he returned) to get all the nuances right. He started out making from scratch, and built his own tooling to work the aluminum into the final product.
I have watched the market become crazy on the wings...used to be a used set would top out about a hundred bucks, and I have missed a couple sets over the years that went from parts trailers for $20. Suddenly they went nuts...to the point where a rough used pair starts on ebay at $175...and usually ends up at $275. My Airflyte will require a set of 42" wings. Forty-two inches! That is huge and will stick out like a sore thumb. I definitely want them to be only as beautiful as Tyler's.
After playing around today I'm now in the "shift the screws" camp.
BigBill had a great idea but the Shasta framing is so flimsy I'm concerned tapping the screws any harder to loosen them may weaken the support I need for the wings. On my Forester with ripped 2x studs it would work. And the screws are too small to notch for a screwdriver. Enlarging the hole to get a grip (as a friend suggested) opens me to leak issues.
So I'll mount the wings in the same place (as Ten suggested) with the screws shifted.
It took me a day or so to sell myself on paying what seems like top dollar for wings. But the best usually costs more, that's just the way life goes.
"Price is what you pay. Value is what you get." Warren Buffett