I really feel for ya Tony…… 😥
I`ve had this happen to me with a brand new frame bb build. Pace RC305 (remember them!!!) and a Royce square taper (Yes a Royce!! :oops:)
So, what did I not do….. have the threads chased to remove any anodizing that may have been there. drive side went in ok, the non went in roughly 1/3, got a little tight by hand and so got the tool out. Approx 1 1/2 turns later it was jammed solid and would not budge. 😯
After pacing up and down/cursing for a few mins I knew the only way was to cut the cup out of the frame (something I have done before)
Here goes,
You need a good standard hack saw blade and preferably a handle to hold it in (or tape round the end to grip) and start cutting. The aim is to make 2 cuts to form a 1/4 segment and working your way through (be patient) and when your almost through take gentle slower cuts and you can hear the difference between the cup and when the blade just touches the frame threads and STOP!!! ❗
Once done then all you need is to break out the 1/4 piece and then the rest will come out quite easily. 8)
I`ve actually done this 3 times over my 26 years of “fettling with bikes” one was with a Ti frame as well….. 😯
Just wish I ad some pics to show!