Is this pulley trashed? Pic

[scouttster]

All the keyholes I have ever seen were straight runs.
This one is a straight run with a notch area at the end. Not sure if this is the way its supposed to be..

[keith]

It's not right, but I'm not sure it couldn't be used. You might get it repaired with a weld fillet and remachined, but it might work as is with a good key and tightening the crank bolt to spec.

[takza]

Looks like cracks near the keyway?

[Petros]

This is not good. the Pulley has a harmonic balancer built into it, it will not function properly if the pulley can move back and fourth. It appears this is caused by a rotating harmonic imbalance. It may have run with a loose front pulley bolt allowing movement to erode the metal way. It should be replaced, and probably the key as well. I would just get another one from a wrecking yard, they are not expensive. I think I might have a spare or two in my garage (local source would be cheaper, no shipping).

I am not sure I would try welding it, you might over heat and burn the rubber isolator under the pulley.

I know the early Mazda Miatas had a similar problem and they came up with a fix. You clean up the damage parts with a file, and you install the pulley with a new key and before you put in on you fill the void with "liquid metal" or epoxy, or high strength lock-tight or something similar, than torque down the pulley bolt (also with lock-tight on it). If you use lock-tight you will want to put it all over the shaft and all the mating parts to help hold it in place. It will keep it from moving and doing more damage. I do not think this is a permanent fix, but it will get you running. I suspect it will eventually work loose again. I would just replace the pulley, key and possibly the bolt with used parts.

Good luck.