This is what I suggest , clean the shaft and the pulley so it goes on the shaft nice and easy, once you have that done fine a set screw the same size as the one on the pulley, chuck it up in battery drill and put a sharp pont on it, then put the pulley in place and line it up true, then put the cone point screw in place and tighten it down, this will mark a spot on the shaft, now take the wheel off and drill a hole just a bit over the size of the right set screw about 1/2" deep, put the wheel back in place and put a new longer set screw in place..
This is not as good as a key but because it's hard to sheer off a Allen set screw it should hold for a long time...
Allen set screws are 170,000 psi. DHT..the norm for a 5/16-18 size.
You may also want to use a Alen Cap Screw, because set screws do like to strip easy and you have the room it and you can use a bigger Allen wrench and if you do strip it you can always grab the head and take it out...
Originally Posted by Kristin D
I am going to visit a friend who has a machine shop tomorrow to make a few parts for a project on his milling machine. I have gotten the wheel and pulley off the Willhoit band saw finally with a lot of tugging with pullers. Both the wheel and drive pulley had spun in its past life sometime and there were no keyways or flats on the shaft. Since only the pulley has a keyway and I doubt he has a shaper to cut one in the wheel, I was thinking the best thing would be to mill a flat on the shaft so the set screws have a place to grab without deforming the shaft and making pulley and wheel removal another two week adventure. The shaft is stepped 5/8 on one end for the pulley and ~.590 for the 6202 bearings, what size flat would be recommended ¼ across or 5/16 I dont want to take off too much material.