The PTO pulley on my 3212V had the keyway wallowed out so to salvage the pulley I cut a new keyway then drilled and tapped new set screw threads for it. I don't have a broach set so I used my lathe with a boring bar and manually moved the carriage to take 0.005" per cut to make the 3/16" x 0.09375" deep keyway.
Lathe setup:
Boring bar and bit:
Pulley with new keyway partially cut:
Bad keyway:
New keyway:
Complete with set screw:
My cutter bit was 0.005" too narrow so I had to hand file 0.0025" from each side to make the key would fit but overall the job came out good for a first time learning experience.
Not thought of doing it that way. I use a milling bit the right width, bore down & make a half-round key slot, then finish the corners with a file. I'll try that way the next time & see which works easier.
"Do any of you do work like that for fellow members?"
I made four sets of Mackissic chipper/shredder hitches and clutch pulley assemblies for Ambler at Simple Tractors. Traded them to him for a chipper/shredder.