Has anyone in the Lethbridge area got an extra pulley I could borrow or buy? I have extra's but they are 2 hours away. I need to sort this out soon so I don't get towed.

Sorry Ian, all mine are on engines right now.

Sorry. I think mine went with my engine when I got rid of it.

Sorry, just acquired a b20 powered car, so no spares yet.

Paging ChrisM! He should have a spare or two, he seems to have a few of all things vintage.

Ok found one and got my car home. I had been driving with the fan removed and just using an electric one. My question here is did I overtighten the pulley or does the fan reinforce the pulley and keep it from flexing and breaking?

The exact same thing happened on my B21, ever since then I've been advocating reinforcement.

Probably over tightened your generator/alternator...ouch. The fan does reinforce the front, but I've run my B20 for years without a fan attached, without issue.

I'll make a plate and try again. I suppose as long as it's charging and not squealing that's all we're looking for or is there some golden rule?

Tighten until you have about 1/2" of belt deflection. That's what I always do.