Without a precisely fit bushing in a barrel vise, you may not get enough surface area contact to grip with the torque needed...which is why I always use an action wrench held by a vise.
I'm surprised no one's mentioned the tool of choice for this, and it ain't a dremel....a pipe wrench will never slip on a barrel nut.
If the customer has a smooth nut, I tell them up front it's going to be trashed. Slotted, I'll give it a limited amount of effort with the nut wrench to "save" it. But they're so cheap, I regard them as one notch above "disposable" and it's not worth expending much labor trying to get one off without buggering it up.
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