[brucey]

I drilled/tapped some new holes on the face of the pulley, bringing them just 3/4" from the center and used a file to grind some of the shaft down just slightly, hoping maybe the top of it had ballooned out somehow from forcing it. Still a no go. Grade 8 3/8" bolts and an impact gun on a puller does nothing at all but make a bunch of noise. Going to the machine shop tomorrow morning, if they can't get it out then I'll have to cut the pulley sadly ): Such a beautiful piece too. Once I get everything aligned and operable, I do plan to re-do the front bracket. Yes, I know I need to focus on one problem at a time, but that bracket has had too many 'oops' at this point for my tastes to leave it on there permanently. On the bright side though, I seem to have invented a new way of welding. Just stick two pieces of metal together and it instantly corrodes into one solid piece!

Shadetree: Good info to know, and hopefully can help someone out one day. I didn't realize it could corrode on something that tight. Pulley is 6061 aluminum, but shaft is steel, what kind I am not sure. Buh. Learning experience eh?