misaligned keyway - stepper shaft vs pulley

[dsc]

I'll swap the motor and hopefully get a properly cut one. The misalignment is pretty severe, so filing it down would be a long process, especially with the keyway being awkward to work on and the material being hardened steel (or whatever the shaft is made of).

Regards,
dsc.

[magicniner]

I'll swap the motor and hopefully get a properly cut one. The misalignment is pretty severe, so filing it down would be a long process, especially with the keyway being awkward to work on and the material being hardened steel (or whatever the shaft is made of).

Regards,
dsc.

Motor shafts turn & mill fairly freely, I had to reduce a 3/4 Hp 3 Phase motor shaft size to keep my mill internals standard when upgrading it, I think you'll find a file or even Dremel with a bur will do the job nicely, the pulley should file easily and as Swarfing said appears to be the location of the problem,
Regards,
Nick