In stripping down process and I need to remove the door "stop" catch that is in the jamb, the one that catches the rubber wedge on the door. Right, so...how does one get those nasty little rusty screws out?

And why are new rubber wedges $11 each?????

rusty screws can be a pain
so you can cut a slot in the head with a dremel tool
then use a torch and get to hot then use a straight screwdriver

or drill and tap it out

or weld a bolt to it and use a socket

good luck.joe

Try PB Blaster.
Spray it on and let it penitrate for a few minutes. Tap the screws lightly to loosen the rust. Then like magic, out come the screws.

With rusty Phillips screws I find using a fine scribe to scratch out the rust from the head of the screw makes a big difference. Also using a good carbide tipped screwdriver makes a big difference. Apply valve grinding compound to screwdriver tip increases the grab of the tip into the screw head. Remember Philips screws are sized the most common are #2 Use the best fitting (correct size) screwdriver is paramount.

Of course like others have stated use a good penetration oil. Turn the screw in the tightening direction first to break it free often works before turning in the counter clockwise direction.

I have a small battery powered impact driver typically used for construction stuff. With a phillips bit (that fits well, as mentioned above) you can lean on the screw to hold the bit in the head and pull the trigger (the gun being switched to reverse of course). That can work. The ideas above are all really too.
Kirk

I tend to use the Bosch power driver bits when dealing with tough screws. They are ribbed and have a great bite compared to all others available:

https://www.boschtools.com/us/en/boscht ... 2-29593-p/

In really tough situations I use their Titanium coated version.

https://www.boschtools.com/us/en/boscht ... 2-30569-p/