Rotor screws are toast
 

The screws holding the rotor to the hub are soft and are hard to get out. Tried heat, penetrating oil, wd40 and no luck. If I drill the head out am I looking at some major issues? Can I take it to a machine shop and have them thread it for me again? Doable?

Have you tried an impact screw driver? They are made for taking out troubled children like this? If you a Sears, Home Depot or Lowes I have seen them at all of these locations.

They are not that long and mine required the use of this to get two of the four rotors off.

Best of luck!

I used a lot of heat from a propane torch to get mine out. An impact wrench is a great suggestion. After that, drill a hole down the middle of the screw and use a wrench and an "easy-out" which shouldn't harm the threads (if you're careful).

there are some good videos on this up on youtube. drilling it out is not that hard.

I agree on the impact driver. You'll need it eventually, and it does the job instantly and reliably. I had to use buy one when doing my first rotor change a decade ago (!), and have needed it once or twice since then. I think it's whenever someone ELSE does the work and puts the damn screws on too tight.

Impact driver is how I've gotten mine out. And I use anti-seize when I put it back together.
I have had to drill out the screws (on an Acura). It's a PIA, but possible.
Good luck

Thanks guys. I'll add an impact driver to the arsenal. I want to avoid drilling. Somehow it doesn't work for me. Too many ones still stuck in the car! :(

I had to drill just one of mine, then I used an EasyOut on the end of a Impact tool. Drilling was not that bad...just enough to get the EasyOut to bite.

I just replaced the fronts this past weekend...didn't even bother with anything else, I used an impact screw driver and they came right off.