A "Don't do this" special report, with pics. Big ones.
 

Hey, lookime, I'm drivin my ma's Grand Cherokee for the weekend.

Let me show you why.

http://www.subaru-svx.net/photos/fil...u_S./17660.jpg
The pulley's keyhole.
http://www.subaru-svx.net/photos/fil...u_S./17661.jpg
The crank thingy's key.

I have a new pulley from Dayle, which should be stronger being that it's billet and not cast. Can't put it on though. There's no point until i can get a new key thingy.

I was so excited, too. I picked up the pulley, some belts, some break pads, and a tranny cooler from FedEx and went to install it all, but it seems if I were to drive any longer theres a chance the key would have completely eroded away and I might have crashed into something due to the PS becoming unavailable.
Man, turning that thing without PS makes the XT6 without Cybrid seem lightweight.

Highlight of the day was the Stang Big D pulled up in. 90% restored drop top.

http://www.subaru-svx.net/photos/fil...u_S./17665.jpg
The engine.
http://www.subaru-svx.net/photos/fil...u_S./17664.jpg
Waving bye to the vehicles.

I have a short clip of the Stang idling, and one of Danny riding on that ludicrously small 26cc (3bhp) motorized bike on the wall.

Oh, here's the new pulley next to the old one. Obvious size difference.
http://www.subaru-svx.net/photos/fil...u_S./17669.jpg
But the red one is lighter. Hmm...

Oh, question. What is the trick to get the key out?

I can pull the key out of the shaft with plyers but first the sproket on the crank for the T-belt has to come off. The key drives the T-belt sproket and crank pulley. Right? So the T-belt has to come off to get the sproket off.

Most people have trouble getting the crank pulley off and that's done in your case. :D

We are setting aside Sunday to get this thing back together. Hopefully I can get a key thingy today.

Anyone know what the key thingy is made of?

Whatever it is I hate it because it broke in half. Iv'e got it apart right now. Trying to get the piece out and the cams aligned.

How do you remove the crank sprocket?

The answer to that last question would be to clean your crank after water pump failure. =D

Picpics.
If only this tiny thing were titanium.
http://www.subaru-svx.net/photos/fil...u_S./17770.JPG
The hole.
http://www.subaru-svx.net/photos/fil...u_S./17772.jpg
The tool.
http://www.subaru-svx.net/photos/fil...u_S./17771.jpg
The shaft. Baked on shizzle.
http://www.subaru-svx.net/photos/fil...u_S./17773.jpg
Broke.
http://www.subaru-svx.net/photos/fil...u_S./17774.jpg

I would clean up that shaft pronto before you put on the new pulley. You should use crokus (sp) cloth, or very fine sandpaper.

That was the last thing we did Sunday night. A new sprocket was ordered today, being that we destroyed the old one. It was dirty anyays. Won't go back together 'til Subaru get's that thing here. They are slow as hell. Took two weeks just to get a thingy of touch-up paint.

Got that stuff on 2-day. Installed it about 7 hours ago.

Apparently my timing was off by 4 teeth, according to Danny. Right now I can safely say I have never felt it pull so hard. I have no trouble peeling out. =D

However, at random times I will get a jerky stutter like it doesn't know what it's doing. =|

Also my idiot lights flashed for a split second. I thought my belt was going to fly off.

Another weird thing I noticed, it's quieter. Doesn't make nearly as much engine growl or exhaust note.
=/

T cooler goes in my next Saturday off.