Timing pulley slipping on gearbox shaft

Im not certain this is the correct forum category for this question... if not, please recommend correct forum topic.
I have a custom built CBC Hotwire machine with 2 animatics motors (x&y), Apex dynamics gear boxes connected to steel timing belt pulleys. The x pulley is slipping a little. Enough to make circles with opposing flat sides. The x gearbox shaft key is worn & The 2 set screws have worn into the shaft a little. I can still run machine but it’s off a little due to x axis timing pulley play on shaft. New gearbox is $1,100 min. Looking to attempt fix before buying new gearbox and pulley because it will probably wear new shaft again. Looking for a suggestion on the strongest locking type pulley on the shaft to avoid future slip & wear on shaft and pulley key slot. I.E. adding flat sides to shaft for set screws, adding more set screws on new pulley, custom fabricating a timing pulley onto taper bushing? Or other ideas. This is probably a common issue I’d imagine.
Thanks Bill

Hhy don't you just remove the setscrews one at a time and drill a hole in the shaft and replace?

Put loctite on the shaft and pulley.

Thx or idea. do you recommend the strongest Loctite? Could I still pull of the pulley later on with pulley puller?

not sure if reply went thru. thanks for suggestion. I think that would help. I'll probably broach a new key slot in the pulley bore too. add a couple more set screws. and loctite everything.

Hi William - I Only use loctite on my pulleys. No screws or keys. I use permanent grade loctite. If you ever need to get them off a little heat from a heat gun and they come off easily. But the plan is for them never to come off. Peter

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Originally Posted by WilliamKinsey

Thx or idea. do you recommend the strongest Loctite? Could I still pull of the pulley later on with pulley puller?

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Yes, I'd use red loctite. If you need to remove it later, heat it with a torch, and you'll be able to pull it off.

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Originally Posted by ger21

Yes, I'd use red loctite. If you need to remove it later, heat it with a torch, and you'll be able to pull it off.

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Thanks for info????

Thank you for the recommendation. And link. Whatever I end up doing loctite will be involved.

If you have a gap to fill as a worn shaft you might look at the Green Loctite, read the spec's before deciding.

Thanks for input. ‘I’ll check out green loctite