Repair or replace?

[whydontu]

Perfect simple solution. My father always said "when all else fails, cheat"

 

[mbond]

I think that probably nothing would be fine. That setup will be fine for sure. But if you want the most support for the cracked section, and strength overall, you should rotate it 90 degrees.

It may seem counter intuitive, but 'closing the crack' won't help in the same way that supporting the metal around the crack would. And moving the joints in the supporting ring as far away from the weakest section will do that the best.

I don't think it can make any practical difference in this case

 

[Susquatch]

I agree with @mbond. Especially when you consider how the cracks were made.

I'd also suggest grinding down the head of the pin so it isn't being further pressed into the hub. Both ends should be recessed a bit so they are not proud of the hub. Level is ok. Proud is probably not.

 

[140mower]

Perfect simple solution. My father always said "when all else fails, cheat"

..... He was a wise man.

 

[Elektrishun]

I think that probably nothing would be fine. That setup will be fine for sure. But if you want the most support for the cracked section, and strength overall, you should rotate it 90 degrees.

It may seem counter intuitive, but 'closing the crack' won't help in the same way that supporting the metal around the crack would. And moving the joints in the supporting ring as far away from the weakest section will do that the best.

I don't think it can make any practical difference in this case.

Due to nearby shelving I couldn't easily get my head around to get a frontal view. So I took pictures when the collar was in both positions and tightened down. Originally I placed the collar the way you suggested.

The collar fits really snug. After tightening it down in the position shown on the left I changed my mind and moved it into the position shown on the right.. Even with the screws fully backed off I had to gently tap the each part of the collar to get it off the pulley. It fits like a glove. I will consider your suggestion.

 

[Elektrishun]

I agree with @mbond. Especially when you consider how the cracks were made.

I'd also suggest grinding down the head of the pin so it isn't being further pressed into the hub. Both ends should be recessed a bit so they are not proud of the hub. Level is ok. Proud is probably not.

It may not look like it but I carefully filed both ends of the tapered pin flush to their respective openings before installing the clamp. Seems like it went on pretty good no matter which way I installed it (see pictures above).

 

[mbond]

I think you will be fine with any of these options. I'm sure this forum gets searched as well, so for anyone else, I just want to mention a comment on this configuration versus the other possibilities