I ended up doing a fair bit of research and came to the conclusion that as long as the tool doing the cutting is fresh and sharp, it would reduce any smearing which would block the holes. I used a brand new reemer and indeed the vast majority of holes were visible afterward. Saying that, I don't intend to ream it next time as it's only shy by about a thou, so once it's been dropped into the pulley, I'll heat it up which should be enough to drop it on the shaft. Probably need a bit of elbow grease to loosen the pulley up after that but it'll negate any possible flaw I might introduce by messing with the bore on my old machines.

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