Unable to get part through Audi tradition or Audi themselves

[andy j]

I'm in the process of fitting a new cam belt, water pump, valve stem oil seals, etc. I have removed the Cam timing pulley (034109105) and the key has broke on it. I found the pulley in stock on Audi tradition but was unable to pay for it. I phone Audi Carlisle they said they could order it but it was on back order and would be week before it would turn up. I emailed Audi Tradition about the fault and i got a phone call from them. They told me that the website has been faulty for a while but i could get my local Audi dealer to order direct from them. I phoned Audi Carlisle back and they told me that they couldn't order the part. I explained that i was told that they could order it through Audi Tradition. They just said its not possible to get the part because of the age of the car and there is no way of getting me the pulley then hung up the phone.
So now i am wondering how how i can proceed with this. I'm kinda screwed without the pulley so was wondering if anybody on here could point me in the right direction?

[Tractor Dave]

Terrybullone on here makes an excellent replacement. Suggest you get one from him.

[andy j]

Terrybullone on here makes an excellent replacement. Suggest you get one from him.

It's not the crank pulley that has snapped I already have one of Terrybullone crank pulleys to fit. Its the Cam timing pulley that the key has snapped on.

[twoqu]

Three options, cheapest to dearest.
1. Place wanted ad for good used pulley.
2. You could drill and dowel the camshaft/pulley.
3.Look at an aftermarket adjustable pulley.

Agreed its getting increasing harder to just keeping them going when you have the once in a car's life problem. I guess its down to us to innovate, a bit like James's crank pulley.

[twoqu]

I looked at this before and I could not see why if you had the capability it would not be possible to cut a slot into the pulley of an appropriate size to accept a traditional metal key. I appreciate that it can only be a 1/4 moon key rather than the usual 1/2 moon.
At least one aftermarket adjustable pulley uses a seperate component to mate the pulley to the camshaft. Pehaps someone from an engineering background could design something similar. There must be a few damaged pulleys out there that could be reclaimed.
Some engines only use taper or those diamond washers to secure the pulley rather than keys.

[terrybullwon]

I doweled my Tommis billet adjustable pulley as the key was made of utter ****.

Lined it up in a mill mounted to the came and just drilled it into place 180 degress out to the OEM one then using a dowel to keep it all in check. Ill find a photo i am sure

[twoqu]

Like this! The dowel is 6mm.

[andy j]

Just been and seen a local machine shop and he is going to cut a key in the pulley for me. He also suggested Dowling it. Thanks for the help guys!