I'm in the process of building out my long block and have hit a roadblock while installing the pulley.  I can get it on just short of where the stock retaining bolt will grab the crank nose.  I've been using two longer bolts to draw the pulley onto the shaft.  I've pulled the pulley off and inspected the keyway and the bore.  There is a bit of a lip - just detectable with my dental pick - about 1/3 of the way from the nose of the pulley.  The nose end has the larger diameter.  I've cleaned and inspected the keyway.  A loose woodruff key goes on about 1/3 of the way from the nose - about equal with the ridge on the bore - and binds up.  I've tried both the used key that came out of it and a new one - both with the same binding issues.  The engine shop didn't indicate the crank has been changed out.  The pulley stayed home.  BTW - It was a breeze when I took it apart 3 months ago.  Pulley came right off - no struggles.
I don't want to hammer it on and was reluctant to use a lubricant such as WD-40.  Nor did I want to dress the side of the woodruff key.  One thought I just had is to lightly dress the side of the keyway with an ultra-fine file just to see if there is a burr or spot of rust I haven't found.  It won't take much to bind stuff up.
For fear of really screwing things up, I was reluctant to go much further without some input as to acceptable courses of action or other things to consider.  What are your thoughts?