Mark,

Just going from other engines here, so I don't know exactly how the bolt, fan and crank are coupled, but is it possible to drill out the bolt close to the threads and retap the threads - or for that matter drill it out a size larger and retap the threads and use a larger bolt.  A lot depends whether the bolt is what centers the fan or it fit's into something that centers it.  Anyway - just a thought... 

Not from experience, but I have worked with tool steels a lot.  You can probably use a carbide drill bit to try to drill the ez-out out.  The face has to be flat - it may be after the weld broke, but you can use that diamond bit or a rotary diamond file or just a grinder on a dremmel to get a flat surface or concave dish in the bolt face to start the drill in.  Then try a carbide drill, work slow (meaning a medium speed and let the drill cut - not much pressure) and use lots of lubricant.  Carbide is very brittle and if it catches a corner it will break.  Further, it will try to slide off the hard metal and cut into the soft stuff, so keep it centered.

Here's a page with a drill like the one I used to use on hardened tool steel - I think one of these would work.

http://www.cjtkoolcarb.com/catalog/Durapoint/style155/style155.htm

Also, here's some suggestions from a forum (not cars, but the concept is the same): http://www.advrider.com/forums/showthread.php?t=153648

Once the ez-out is out, you might try enlarging the hole in the bolt with a left handed drill bit.  That's a drill bit that cuts in the opposite direction - that might work the bolt out if you are close to the threads.  Heck, it's worth a try....

Dan
Los Angeles, CA
"Winky" the '85 Westy Weekender

> On Oct 28, 2011, at 6:21 PM, Mark Hineline wrote:
> 
> 
> I have an '82 that started its life as a diesel but was converted to
> aircooled at some point in its life. I have reason to believe it was
> in the early '90s. In March, the bolt holding the fan to the
> crankshaft sheered off. I managed to drill through the remains of the
> bolt, but then broke an ez-out inside (the twist drill kind, not the
> square kind). I've been fooling around with this thing for months and
> decided to throw in the towel and call a welder. The welder said: drop
> the engine and bring it in. He has a machine that will disintegrate
> the ez-out.