Thanks - I see what you mean and I tend to lean in the direction that it will be fine as is. Hopefully I can find a good pulley but the broken one will be plan BLike stacking a "disc" as it was called above on the broken sheave. Or doing a buildup with whatever means available (aluminum braze, traditional braze, hard solder, or similar hot methods) and turning the repair smooth. JB weld can do amazing things on parts that only see moderate forces at the repair joint, so that combined with the disc washer would make a visibly appealing repair.
It looks steel, so that opens up more hot methods to use.
The chip is really minor, I think the function would be fine and you are only chasing aesthetics.
Rick