Trouble removing KM3 variable pulley from motor shaft

[Bkannry]

I need to replace a noisy barring in the motor but am unable to separate the pulley from the motor shaft. I have removed the set screw and soaked the key way opening between the shaft and the pulley assembly with penetrating oil. It won't budge. If anyone has any advice I would appreciate it.

[bloke]

If you have access to a press, it should pop off there easily. Put a bolt and a washer in the thread in the end to protect it.

[Bkannry]

I couldn't get at my press last night-it's buried. Big mistake! I tried to remove the pulley with a gear puller and cracked the the thing. Too make things worse it's still stuck on the shaft. The crack is about 2.5 inches. I have been told these are very hard to come by. Is there any hope to repair it? What kind of metal is it and can I braze or weld it? It does not appear to be bent at this point.

[bloke]

They are cast iron and I think they are chromed on the running face. It would be possible to turn up a steel replacement as long as the running face was polished enough to stop the belt wearing.