More screwing around with postimage. It seems pretty good actually - free and no sign of an ad or even upcoming ads. I like it.
So more turning of the new pulley sheave
New sheave on the left, partially repaired sheave on the right, center boss for repaired sheave in the middle.
So the boss went in some dry ice, and the welded / turned sheave went in the oven.
That all worked, and I had a go at broaching and that worked as well.
I added scotch keys to the repaired sheave just for good measure.
Since I was screwing around with dry ice today, I threw some in my evening restitution for dramatic effect.