I would take my camera and the saw back to HF and tell them I want another one in exchange. I have had no issues with mine other than alignment of guides to cut straight. I fixed that myself with a shim in the right place. Also our local HF has no problem taking stuff back if within the warranty time.
I don't think you should be so fast in condemning HF so fast. These kind of things happen with many of the suppliers from time to time. I would first call your local store and see if they will just give you the pulley before you have to load the saw up and take the whole thing back. To be really nice they may even give you one off a saw they have in the store instead of waiting for one from their parts department. I guess I just don't let this kind of thing bother me to much if they handle the repairs. Seems odd that just the outer part of the pulley is all that is out of wack. Good luck !!!
I thought the same thing about only the outer part being out of wack. My first thought was maybe the saw took a good hit and bent the end of the pulley somehow. And if that was the case maybe the transmission had some problems because of it. That was why I suggested getting a different saw. Either way stuff does happen from time to time and I know I have had good experiences with HF and would not put them down over 1 or 2 problems with things.
My experience with Inspections of Parts in a production house is this. Depending on the quantity in a production run depends on how many they randomly check from that run. If they get no problems from the ones they check, then the whole batch is accepted. That does not mean that there are no bad ones. So on occasion someone will get a bad part. This happens even with the best manufacturers. It is when it happens quite often and with no help rectifying that I will say something bad.
I have even had things like craftsman power tools bad from the box. They do not really inspect most things like a final QC any more. They do the random checks and if that is good, then the whole lot or the lot for the day is considered good. And the poor smuck that is board to tears putting the pulley on does not pay any attention to it he just slips it on and tightens the screw down.
The think looks like it the last was cut on a offset. maybe they were trying to make a cam.
I have had some good luck with most of the stuff I have bought there. Being on a low fixed income keeps me from buying the top brands anyway. My 4x6 bandsaw is about 10yrs old and still works good. Had to replace the motor though because the plastic fan inside broke and froze the original. But I can't complain as it lasted 10yrs before it broke.
I'm surprised to see a machined aluminum pulley. When I was in the market for a horizontal band saw (the smallest, manual one that they sold) the display model had a stamped steel (mystery metal?) pulley. One of the reasons that I didn't buy a HF unit. What saw is this off of?
In any case---Return the entire saw; even IF parts are available, it will take months to have one shipped from China. As you said, the damage done to the pulley may also have caused some hidden damage that wont show up until 1-day after the warranty.