Don
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Sounds like you got about as far, or maybe a bit further, than I did over 20 years ago before admitting defeat and cutting the belt.
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Burred over and damaged set-screw holes were definitely a feature needing care to get things apart without significant damage and requiring thoughtful re-working to prevent a repeat.
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If I recall correctly with the whole unit removed I was able to pull the bearings with the shaft sort of in place then tilt and slide to remove it so I could operate on the pulley mount area to de-burr et al.
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Mine was on the final version of the sheet metal box stand. I'd already pulled the centre panel to fit shelves, doors and drawers for storage. Before re-installation I added a couple of extra holes, with covers, so everything could be re-assembled in place. With everything nicely prepped and clean it all went back together very easily.
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Clive
