[DavidG]

Frank,

Forget # 2 and 3 for the reasons previously stated. In #3, that dimple you refer to captures the spring for the camshaft thrust plunger. If you file a 1/4" off it you will likely ruin the cover. Likely 4 won't work as your ledge-less timing gear cover is probably not the unique '33-'34 version of the timing gear cover as stated above. But if by chance it is a revised version of the '33-'34 then this is a viable alternative. In one of my recent posts I indicated how to identify the '33'34 version based on the location of the boss for mounting the generator.

I have a good used '33-'34 crank pulley in case you break yours in the process of removing it. It will come off the end of crankshaft without damaging the crankshaft as there normally is oil in the immediate vicinity and corrosion is not normally an issue. There are no pins or bolts involved except the big one on the end of the crankshaft as described above. The pulley slides on the end of the crankshaft and a notch at the back end of the pulley engages a Woodruff key that is inserted into a slot in the crankshaft. It is held in place by the big bolt that doubles as the engagement point for the hand crank. Once that bolt is removed all that is holding the pulley in place is friction. But there's plenty of it hence the need for a puller in 99 out of 100 instances. Most of that friction comes from the oil seals in the timing gear cover and oil pan as mentioned above.

I also have a spare front motor mount bracket, but if you stick with #1 you won't need it.

If this were my car I would remove the grille and radiator to gain unfettered access to the front of the engine which would then make using a puller on the pulley relatively easy.