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Keyway is shot

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This may be a stupid question. The keyway is shot on my snowblower's main drive shaft. I put on a new pulley and there is considerable play. Is replacing the shaft the only alternative or can something else be done?

Also, any other suggestions on how to make sure that a 30 year old yellow Allis single stage snowblower is dependable next winter?

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Thanks for the help Fred, I would not of thought of having a second keyway cut without your help. I still have to get the shaft pulled out. This is not much of a priority as I don't believe that it will snow again for a while.

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Any decent machinist can cut you a new keyway on the opposite side of the shaft. If there is other wear on the shaft than just the keyway, you may have to have it welded up, turned down and recut. All of which is by way of saying that it can get expensive quick unless one is good friends with the machinist. Sometimes a visit to a school shop teacher can be helpful, if he's willing to do it to demo a technique to his students. Another alternative might be to substitute a "Browning" style (clamp-on) pulley, if one has the space. That can take up a LITTLE wear on the shaft.
Good luck, Fred

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On applications where parts were not available or did not warrant the cost of replacement I have straighten out a keyway grove with a whizzer wheel or file and ground down oversize key stock to custom fit the new dimension - rude and crude....... but it can get you out of a jam or keep you going until new replacements are available.

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