I was changing the cambelt on my Masterace last week when i noticed that the woodruff key holding the bottom fan belt and air con pulley to the crank was worn, under closer inspection i found the pulley's key way also to be worn and the key way in the crank to be significantly larger than it should be, has anyone else come across this and if so what repair did they do.

thanks

- (#9546) Chris, 24 Mar 04 13:18

Chris. The only way that the keyways can enlarge is due to the pulley moving,radially, on start up and shut down.
No doubt you have torqued the securing bolt correctly and this will ensure that this radial movement is halted temporarily. However, over time, the pulley, due to it's mass, will start to move again and, the "hammering" of the keyways will get worse as the clearance increases.
Before it gets really expensive, a new key should be made, which fits both the crankshaft keyway and the keyway in the pulley. Where wear is extreme, the key, sometimes, has to be filed up with a step to accomodate differing widths of keyway. Any steel stockist will sell you a piece of keysteel and it is quite easy to make up a new key which fits, snugly and correctly, in both keyways

- (#9546) John Davis (Leics), 24 Mar 04 14:11

Had the same problem ( keyway worn ) when my liteace pulley bolt broke.
I coated the new key with a VERY thin film of Fairy Liquid ( Sorry for endorsing a product:-)) set it in place and then applied a 2 pack epoxy adhesive ( Araldite type ) to the worn area. Just before it was set hard I removed the key. Left it to continue to harden and then filed it to flushness. Refitted the pulley with a new bolt and have had no problems since.

- (#9546) stephen judge, 24 Mar 04 15:26