Bob & Doug,
Well 3+ hours later, none of the autoparts, hardware, flea market had a bearing puller. I did find one mechanic open and his Snap-On puller was about an inch thick like Bob said so it would never fit past the 3/8" clearance between the outer rim of the pully and the frame casting.
Doug, there is a burr but since the pulley will only shift 1/16" in or out and it's smack in the middle area where the set screw was there is really no way to get to it. I did try holding a 1/4" lathe bit down the setscrew hole and rotating the shaft but I don't think it accomplished anything. Too small in the half keyway to even get a needle file in there.
So now to see if I can rig some bit of steel strap behind like Bob described and rig something to press a screw on the shaft, I did buy a cheap 2 jaw puller with rivited flat jaws just to get a block and hardened screw to adapt. One of my other thoughts was I have some short pieces of 3/32 aircraft cable with a crimped loop on each end, and thought I may be able to loop them behind the hub, cross the ends over and using a couple of bolts get a pull with the cross bar of the cheap puller.
Wish I had a piece of that abrasive eraser stuff, kind of like a pencil eraser thing I could trim a piece into the set screw hole and polish the shaft that way.
Kristin
Not giving up yet, or getting violent!
