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How does one get the woodruff keys out of the crank either side; a half-moon one on one side and the hefty 'block' type on the other.

Normally you'd tap one end of the half moon type, and it would seesaw out of its groove. Nope. Im at risk of mangling it.

The 'block' one is in there solid too and you cant get behind it, in an assembled engine, to tap it outwards.

Ive tried Plusgas and heat on the crank.

Is there a knack?

Try grabbing the key with wire cutter pliers. That has worked for me.
Other methods reputed to work include:
Arctic Hayes Shock release spray from Screwfix
Weld a flat strip of metal with a slot to accept the key onto the key, use a bit of copper sheet to shield the motor, last resort though.

I had the opposite on the flywheel side. The woodruff had chattered and was a loosefit. I replaced the key, but it is possible someone in similar circumstances has used loctite in the past. You could try scraping the edge with a stanley knife and seeing if that removes any sort of bond, at least sufficiently to get a solvent or penetrating oil in.

RobinSF1 wrote: ↑18 Dec 2024 19:49 I had the opposite on the flywheel side. The woodruff had chattered and was a loosefit. I replaced the key, but it is possible someone in similar circumstances has used loctite in the past. You could try scraping the edge with a stanley knife and seeing if that removes any sort of bond, at least sufficiently to get a solvent or penetrating oil in.

I'd bet it's loctite here too! Otherwise I'd do as you have been or try the sidecutter trick.

thank you. All good advice