69' Handlebar Knobs frozen

[Onelastcast]

Grant
Appreciate the offer. I think i have an idea of what your fixture looks like. I have access to a bridgeport and lathe after hours. I'm pretty pigheaded so I havent given up yet. I was able to work the easyout loose with a small chisel.Time will tell.

[racerx]

Until the remains of the EZ-out are gone, you're basically dead in the water. Like taps & dies, they're hard but brittle and can be reduced to fragments with a hammer & nail set (though the nail set will take a beating in the process). Use a nut or appropriate sized stack of flat washers to pilot the drill and you can handle the drilling chores with a hand drill, as long as you have an experienced eye. 90% of the time, the rusty bolt threads will come out when you recut the threads using an M8 tap (as long as you're centered or very close). There's also plenty of material thickness for a helicoil, if need be. Arc welding is an option, in this location. Wrap the flange area of the bar with a wet rag and the heat of welding with remain well-localized i.e. below what chrome can withstand in the visible portion of the bar. You could plug-weld, re-drill and thread the hole back to original spec. Or, drill the hole large enough to fit an M8 hex nut and weld it into place, using an M8 bolt & washer to locate the threads, with the bar end as the reference point. If you have the skills, then you're looking at less than an afternoon's work, $10 and an as-yet-to-be-determined number of obscene oaths.