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I have seen cases where this damage can be repaired by using,'plastic steel' or similar epoxy steel putty product. Try to build up to original shape/dimension as less filing/sanding is needed. Not a great way to repair, but have had some success with this method. Make sure that balancer/front pulley bolt is tight to prevent any movement which will lead to failure.

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13y ago
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Q: Your Mazda cranksproket key damaged It has a new longblock. The key for the sproket crumbled and damaged the groove in the shaft. Anyway to repair this engine without changing crankshaft. It will not?
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