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TR3driver
Great Pumpkin - R.I.P
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I'll get booed for this, but ... one option if you are really running out of money is still to just put it back together. That front key doesn't take much force, it really only keeps the timing mark accurate. Use some Loctite on the pulley hub, torque the big bolt good and tight, and it should be OK. The back key is more important obviously, but there is a lot of it left. Just clean it up a bit so the sprocket can go into place (with some encouragement) and I think it should be OK as-is. And slot the shims, as John suggested before. (Be careful though not to turn up a burr when you slot them.)
As a side comment, on one of my previous engines the nose of the crank was worn undersize from the pulley working loose. I used Loctite RC601 (along with a new hub) when I put it back together. Many miles later (maybe 80,000 or so, not sure) when I needed to pull the hub for another reason, I was able to get it off with a big harmonic balancer puller, by using a center-drilled bolt in the center of the crank and long bolts through the pulley mounting holes. No heat required.
Obviously not a professional-grade approach, but I think it will be good enough. And if it does eventually give you more trouble, you'll have had a chance to save some nickels & dimes to take the crank to a machine shop and have it dealt with right. But my guess is it will hang together until it's time for another rebuild.
As a side comment, on one of my previous engines the nose of the crank was worn undersize from the pulley working loose. I used Loctite RC601 (along with a new hub) when I put it back together. Many miles later (maybe 80,000 or so, not sure) when I needed to pull the hub for another reason, I was able to get it off with a big harmonic balancer puller, by using a center-drilled bolt in the center of the crank and long bolts through the pulley mounting holes. No heat required.
Obviously not a professional-grade approach, but I think it will be good enough. And if it does eventually give you more trouble, you'll have had a chance to save some nickels & dimes to take the crank to a machine shop and have it dealt with right. But my guess is it will hang together until it's time for another rebuild.
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