Guzzi Flywheel & woodruff key

We have a 1950 Astore/Falcone and the flywheel's come off, sheering
the woodruff key in the crankshaft. We've tried (with a punch) to
hammer it out, tried heat + ice and the only option now seems to be to
drill it out which is frightening. I'm terrified of drilling into the
crank and damaging it or the bearings. Has anyone any advice to offer
please?

 

how about a carbide cutter on a dremel type motor tool?
with care the key could be cut and it's a lot more accurate working with a
small
grinder . the small dremel carbide burr is a 1/8" diameter.
i've used this setup successfully.
good luck, sammm

 

Thanks fellas, I'll give it a go. Fingers crossed!!

 

spark erosion?

 

Off-hand, arc-welding in reverse. Rather than sparks from the
welding rod transferring metal to the shaft, you'd be "sucking" metal
from the shaft (ideally, the remains of the key) to the rod.

--

 

It's an old term for a machining process in which some type of electrode is
used to burn away the metal it gets close to. Nowadays we call it EDM
(Electrical Discharge Machine).

 

it's what happens to men over 50