Originally Posted by
PMK
Sadly, if you were to chrome plate splines, due to material buildup from plating, it would be impossible to produce a proper fit. Add to the, I believe chrome is like other plating processes, and has a difficult time depositing plating material into holes or other sharp edged shapes.
Moisture is certainly not the issue. Fretting is a non moisture corrosion event. The two methods to prevent corrosion, either lubricate the joint, or prevent movement in the joint.
If you truly want a lifelong front pulley setup, take the bolts washer and convert it from round to D shaped. Install the bolt and modified washer and torque to specs. Either yourself or get a helper and in the area of the cutaway portion of the was, weld the pulley to the gearbox shaft. Once cooled, remove the bolt and washer, and fully weld the pulley to the gearbox shaft. Grind it flat and smooth, assuming you got ample weld penetration, and install a new bolt with built in washer.
Doing this will stop relative movement and end the spline wear problem. Spyder are not prone to gearbox failures, so pulley removal can be dealt with at a much later time, if ever.
Myself though, I will continue on the plan I started with to remove, inspect and relubricate at certain intervals.
Actually, after giving the welded on pulley idea some thought, I believe for many of the complainers, this would be a very viable method of curing the issue.