[SEL] Petter Gib Key Update - Need Help!!!

[Paul Maples]

Ok gang I have went from bad to worse on trying to remove the gib key from the little Petter Engine. Since I have no machining capabilities these are the things I have tried:

(1) Pre-soaked the Gib Key with Kroil Penetrating oil for a week to start with.
(2) Tried driving the Gib Key in just a little more to loosen it - it did not move.
(3) Tried driving the Flywheel in just a little to break the bond on the gib key - it did not move.
(4) Used an original Gib Key Removal tool - succeeded in breaking off the tang on the Gib Key.
(5) Welded a bolt onto the Gib Key and used a knocker to loosen it - it just broke the weld on the gib key - done this four times with no success.
(6) Welded the knocker bolt onto the Gib Key one more time, heated the flywheel hub a little with a torch, tried knocker again and just broke the weld.
(7) Tried welding a Hex Nut on top of the flywheel with one flat of the hex nut facing the flat side of the flywheel, trying to make a new tang on the Gib Key to use the Gib Key Puller with - broke weld.

Here are some pictures:

The first picture once again just shows the little 1-1/2HP Petter I am working on.
The second picture shows the Gib Key status when I first started trying to get it out.
Remaining pictures show the current state of the gib key - as you can see the gib key has about a 1/2 to 3/4" now broken off of it now.


http://client.webshots.com/photo/309747100/309747100ygAQhr

So now here in my dilemma. I have no machining capabilities, the key has some of it broken off now, whatever I try next needs to work as I am running out of gib key. I need someone to tell me what they think would be the method most successful for me to try next.

Thanks everyone for the help, this gib key is about to put me in the insane house................I belong there anyway.

Paul