This is an area we have put considerable time and effort into and so far, no failures. We use a double 1/4" keyway with hardened steel keys. We use an RCD blower hub for a 385 series Ford application that is NOT fully finished. You need to call them and tell them exactly what you are doing and they will pull a Ford unit off line before final hone which will give you a nice .001-.0015 press fit on a Pontiac crankshaft. Then we use a hard steel very thick custom step washer Eric designed but can be made fairly easily on a lathe. PM me and I can scan and send you a blueprint for the washer. Then we use an L9 bolt tightened to 230 Ft. Lbs. to hold it all together. So far, it has been a very simple and reliable set-up. I have the bolts and blueprint for the washer if you decide to go this route. As George said, if it was a billet or forged crank, I would consider cutting the nose off and putting a new one on. Cast N, crank, time for a new one.
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