Had I been awake longer when I read your post, I would have retained the facts you had already mentioned instead of repeating them!
As for heat, propane is a no go usually. You really need oxy/acetylene to be able to heat the gear very quickly while not heating the shaft it's on. I had the same problem with a radius arm nut on my bronco. Not even a 3/4" impact would budge it. I torched it with my mapp torch and got it nice and orange but, it wouldn't budge with the impact while hot! Hit it with the oxy/acy and it came right off!
Do you know anyone with a plasma cutter? You could cut half of it off while leaving just enought to protect the shaft yet, thin enough to break loose.
If you use the grinder, I would recommend putting something like a sleeve or nut or even duct tape wrapped thickly around the protruding part of the shaft to protect it in the event you slip and hit it.
Be careful, wear eye protection and good luck!
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