The thing to do is when the pulley is off, is to remove the woodruff key, then lap the pulley to the crank nose, this not only removes the rust but makes the surface nice and a minute amount smaller, I use fine valve grinding paste, takes about 10 minutes, my pulley now is a dead snug fit and comes off with 1 finger pressure dead easy, when putting back on smother the crank nose with coppaslip or similar makes it come off perfect next time.
As said though the tools are ace.
tabetha