Edit: Hadn't read the second page before posting! So for future reference for all;
The standard thing with pulleys these days is to use a taper lock. This is in effect a tapered collar with a split. You ease the collar open with a flat blade applied to the split & slide it onto the shaft. Remove the blade & you have an interference fit (plus a key way). The pulley is machined for the taper lock & slides right on, being fixed with 2,3 or 4 allen screws depending on the size. http://youtu.be/RBjtuetw44Q
or: http://www.fptgroup.com/fenner.asp?title=Taper-Lock-Bushes&pageid=2668
Much cheaper than getting a pulley machined for the shaft, and more versatile as well.
If there's a belts, drives / pulleys supplier near you, I'd go talk to them.