Compress,
Thanks for your feedback. After trying the vibrating sander till I just about lost feeling in both hands, and couple other techniques, I resorted to drilling it. Close to getting it out, once I do, is there a way to verify if the rest of the ignition mechanism is the problem, before I put another cylinder in and get back to square one jammed again? Trying to avoid a trip to the dealer and the $$$.

One locksmith suggested the old cylinder can be repaired to guarantee perfect fit - anyone have experience with that?

Thanks again - this is an awesome forum!
Ray