How do I remove this key

[pontiac428]

Jeez, I just remembered a trick for this kind of thing. Weld a scrap of something to the key. It will heat the parts, and provide you with something to grab onto at the same time. This trick has gotten me out of a jam more than once!

 

[Suzuki4evr]

Thanks John. The more options I have in my arsenal, the better.

 

[benmychree]

For a job similar to that, I welded a heavy hex nut to my vise grip and used the back hammer screwed into the nut.

 

[mcostello]

Side cutters will grab the end and provide leverage also.

 

[JimDawson]

Use a pair of dikes.

 

[markba633csi]

Sounds like lots of us have run into this kind of thing before
Last toughie I had was a stuck socket setscrew in a cast iron step pulley and the setscrew socket was totally rounded. That took some finagling
-M

 

[Jim F]

Sounds like lots of us have run into this kind of thing before
Last toughie I had was a stuck socket setscrew in a cast iron step pulley and the setscrew socket was totally rounded. That took some finagling
-M

That is where I use HF torx bits, sacrifice the bugger, it worked for 1 of my flycutters.

 

[Cooter Brown]

Use a pair of dikes.

View attachment 344580

I do it just like this but with an adjustable wrench.......

 

[Shootymacshootface]

There are a lot of good ideas here, but I would avoid doing anything that will cut or nick the shaft. I have seen many keyed shafts fail and it is always around a feature.

 

[markba633csi]

No wait, it wasn't a rounded setscrew, it was the burr on the shaft after I took the setscrew out. I ended up making a kludge end-mill by grinding off the end of a drill bit and driving it into the burr with my Makita drill.
Worked, removed the burr and freed the pulley
-M