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[Dennis C]

Oops, sorry just realised what you mean, but yes they are easy to cut, they must be, even I can do it in my home workshop.

[papasmurf]

Dennis C you may not be aware of your own high level of skill, give the level of positioning accuracy needed and sizing accuracy needed.
I sometimes cut slot in a pulley for a Woodruff key already installed on a shaft to fit into. Fit meaning what it states on the tin. Just able to tap the pulley on the shaft using a hammer and a bit of wood.
The only tool I use is a rat-tail file. I don't have a workshop.

[PeteF]

Well Papa, if you can cut a key slot accurately with just a file then you underestimated YOUR skills. You shouldn't need to tap the pulley on though. The key should be a tight fit on the shaft but a sliding fit in the slot on the pulley (or whatever) this applies to Woodruff or straight keys (Or so I was always taught)

[papasmurf]

PeteF, the particular application I am cutting the keyway in is for an extreme use marine purpose. The pulley has to be tight on the shaft and the key. Basically the pulley is replaced every year and needs to be broken off not taken off.