Right, the nightmare is finally over!! In this pic you can see an indent where the woodruff had been jammed against the cog and how far apart the keyways were!
Also to give you an idea of the previous owners hamfistedness, at the bottom of the pic you can see a cover for the wiring, those bolts are m8 thread, I figure 1/4" ratchet would undo them with ease. I had to use a 1/2" drive ratchet with longer handle to the leverage!!
This is tool I used to get the pulley off
Having lost my temper and taken the balance belt and the timing belt along with every gear, cog and pulley off that side of the engine and started from scratch it fired in to life! No only did it fire up it ran sweeter than chocolate dipped in syrup!! It ran perfect!! No knocks, no rattles and more importantly no smoke!!!
Then I drove it around the block and parked up back on my drive to see blood all over the floor!! It wasn't oil and after checking I hadn't cut off an arm or leg I realised it wasn't blood so the bonnet went back up and I saw my power steering fluid departing from the bottom of the pump. But it ran and ran so well and I figured I'm sick of walking to work so the easiest solution was to isolate the pump. With the power steering belt removed problem solved!
The leak is where the front pipe joins the pump. Its my own fault cuz I gripped it there when putting it all together the tension the belt. The bearings in the pump did whine a bit before all of this so I think it's time for a new pump and pipe.
Top tip for everyone though, DON'T DRIVE WITHOUT POWER STEERING CUZ IT'S ****** HARD WORK!!!!!
So as soon as I can source a new pump my arms will stop burning, also I will be changing the power steering belt then I'll of changed all the belts. I have been told I can only use Honda power steering fluid so it'll be a trip to the main stealer for some fluid.