I still prefer the "soldering iron + light prying" technique. If done carefully enough, you can use my second technique, called "soldering iron + light pushing" to get it back on, and if you had the desire in the future, you can still screw/unscrew it afterwards.

Buy the full, detailed writeup, complete with instructional videos and colour photographs, for only $15 USD.

On the Mini SNES, I just used a 1/2 inch drill bit and bored out the posts right down to the screw head. Once the plastic was completely bored out, the two halves came apart as if the screws weren't even there. I didn't have to drill into the screws at all. It obviously makes it so that you wouldn't be able to reuse the case, but it took maybe a minute to do all four screws.

This worked for me. I just drilled the heads off the screws with a torque drill.

Delayed reaction is delayed. Nice bump.

Thanks.
I thought I'd post because nobody seemed to respond to that.
Was I seriously the first one to see that?

OK< I have one of those 3.8mm gamebits, and it works like a charm on those pesky security screws...but now I think I've stripped one of them. Any ideas on how to remove it and not damage the catridge?

A Drill would would be optional, or a drill with one of those specialized bits for stripped screws.....dunno if they make em for small sized screws though. If not, just make sure to get a small drill bit so as not to tear up the sides and find a a replacment once removed so you can re-use it.

I finally got the screw out by using a very small flat-head bit with a heavy-duty drill. Unfortunately, I think I also damaged the screw well in the process, so I'll need to replace the back panel of the cartridge at some point. The other 2 screws are still holding ikt together at the moment, though.

I always like to sticka crap $3 soldering iron in there and pry out through the side, destroying the case, and ruining the crap iron, but it does the job. Worked great twice now, then I didn't have another on hand, had to drill the screwheads away with a drill press.

http://www.youtube.com/watch?v=nmk0BexW_rA
I just made this video. Worked really really well. I was fed up with the stupid pen crap... (no offense to people who got that to work...)

PS: For all of you who are thinking to yourself "OMG HE SPELLED NINTENDO WRONG!!?!?! BBQ!!! I ARE TO CURRECT HIM NAO@!!",
just stop. I spelled it wrong on purpose, I don't want my video to get attention from youtube.. it could get pulled or something for containing info that could potentially help you mod your console. And dont think I'm crazy, I've had stuff pulled before... People can still find the video by typing nintendo because I put it in the tags..

Classic tools for classic gamers =)

My father still has one of those lovely craftsmen drills like that laying around. It never fails on us!

Does anyone have the specs for the 4.5mm gamebit used on the N64? I'd like to purchase some with Philips or Slotted heads so I don't risk stripping the gamebit - bit I purchased.