I just put a fair amount of effort (no additional leverage, just a 10" wrench) to remove pedals off a bike teetering on being too rusty to bother with, and on both sides the pedal threads took a fair amount of aluminum with them (cranks are Sugino VPs).
Now I'm wondering whether I'm at fault for being too gung-ho about getting these pedals off before soaking them in ammonia or something (they never gave after the initial movement), or whether they were cross threaded to begin with. I've put waaaay more force into removing pedals before (me with a 6 foot pipe), and all that resulted in was a warm pedal.
Have you seen a properly threaded pedals so seized it took some aluminum with it?
As a side question, how much should I expect to get charged to have the cranks re-tapped? (I can thread pedals on, but not sure whether I feel good about it) Or should I just buy a set of Park TAP-6 taps for about $35 so I can be prepared and then this will never happen again