Paul,

Yours may be too far gone, but I once used a permanent loctite product (I don't remember which one it was) in an application like this and it held for a number of years.  Try looking at this link.
http://www.henkelna.com/us/content_data/192137_LT5338_Shaft_Repair_final.pdf

DLW

On Sep 11, 2011, at 12:21, Paul <wognacious@GMAIL.COM> wrote:

> My girlfriend has been driving my vanagon pretty much daily. Recently she
> said that she thought something wasn't right back in the engine compartment.
> Well she was right, the bolt that's supposed to hold the pulley in place had
> worked itself part of the way out. Upon further investigation I discovered
> that the woodruff key was not in the slot, or what's left of it. It was kind
> of in there on it's side and the slot is no longer a slot it's bigger than
> it should be. One side is square but the other side is not good. I don't
> have the time or $$ to pull the engine out to replace the crank so I'm
> trying to fix it the best I can and hope it will hold up for awhile. Has
> anyone had this problem and if so what did you do? I've considered trying to
> drill a hole through the pulley and into the crankshaft, tap it and run a
> allen bolt/screw in to keep the pulley in place. Maybe make the existing
> slot larger and make a bigger key.
> Any help or insight would be greatly appreciated as I need to get the rig
> back on the road.
> TIA,
> Paul
> 85 WWW, 1.9L