Originally Posted by
Slightspeed
I haven't even touched it yet. I was thinking large quantities of PB Blaster and patience, and maybe squeezing the flange "gently" in my wood jawed workmate table vise.
I don't think anything gentle enough to not damage the flanges is going to work.
Cleanest method would be to take apart the freewheel body, build a temporary wheel, and then either get the freewheel back together in place, or just place the body in a vise and torque it off in the usual way.
You might be able to cut the freewheel body off with a dremel wheel if you are very very careful. Obviously it would be risky. The idea is to cut just not quite through, and then force it open enough to unscrew easily.
There are other hare brained schemes that would probably work.