AAZ crank Wobble. Opinions please!

[theman53]

I wonder how many miles some of his rebuilds actually have. I would ask for a customer reference if it were me.

[Gizmoman]

The D is latest greatest from VW and is capable of handling more torque than the stock AAZ unit.
New bolt for sure, no lock-tite - just the spec torque (no more, no less). It's engineered to stay based on the torque and the two faces mashed together. Pins, the D, the tiny key, all play second fiddle to the mash-up so make sure the end of the crank is nice, mirror flat, and spotless - like brake cleaner clean.

I run a V belt and no troubles so far.

[boomenstein]

Still trying to find someone to do this mod with the engine in the car, I bought a early tdi cranks and pulley. Dreading having to do the swap...it feels like it will be a can of worms opening the bottom end.

[vanbcguy]

Changing the crank in-car is not worth it - you have to separate the trans anyhow so you might as well yank the whole shebang.

Getting the existing crank nose machined in car is something people get done however.

[Gizmoman]

I know it sounds crazy but I've read some posts of guys grinding/filing the crank to fit the "D". It would take some very good eye/had control and plenty of patience. I believe someone had even used a broach and built a fixture to hold it in place (possibly it was Andrew Libby?).
http://www.vwdiesel.net/forum/index.php?topic=27450.0

My AAZ had a good stock pulley and crank and no signs of wear at all. I was rebuilding the engine though so I did the D mod while the crank was out due to all the horror stories. 

Your original post says you just want to drive it. If I were in your shoes, I might get a new stock pulley and bolt, make sure the end of the crank was mirror, flat and bolt it on. Again, only if I was running a V-belt though.
Let us know what you end up doing.