Woodruff key
 

I was disassembling a VVT engine the other day. This particular engine (was supercharged and MSed) started losing power while on the road, stalled and then would not start. So I've already removed the head, and the pistons were fine (I was expecting piston or ring damage). I proceeded to disassemble the short block as well, only to find the woodruff key broken inside the sprocket, damaging the crank keyway in the process.

Is there any upgraded replacement available? If not, does it make sense to get a new one from Mazda and replicate it in billet steel?

Mother of fuck what a nightmare. I think your steel key is a great idea. As long as it is softer than the crank or pulley. Over the miles if there is any play at all maybe it -could- wear on the snout or pulley? I don't know anything though...

My stock key destroyed the crank nose. Not terribly, but enough for me to scrap it. Not sure how a stronger key would help, the bolt backs out.