I had a step pulley from a small belt driven drill press that had a chunk taken out of the uppermost pulley. This is the fix I used. This idea was offered by Carla. I appreciate her help and wish to acknowledge her contribution. And thanks to Jeff J. for reformatting the text. (SWMBO was rushing me to go see our new grandson when I wrote the article).
 Broken pulley |
 Remove broken edge |
Cut a groove to accept the repair:
 Cut a groove to accept the repair |
Machine a large flat washer or other material to replace the broken piece. The ID of the washer was cut .005 inches SMALLER than the diameter of the groove cut into the pulley for an interference fit.
 Flat washer machined |
I heated the washer, installed it on the machined pulley, and then machined the OD to the original size.
 Washer installed, machined, and painted |