BP variable speed questions

Hi Folks,

I am in the process of rebuilding the variable speed drive in my
Bridgport Series I CNC, and am trying to make a decision in regard to
the worn front pulley parts. The keyways are worn in the pulleys and
hub. I'm thinking the easiest (and cheapest) way to repair the hub
and shives are to press the hub out and cut new keyways on the
opposite sides of the hub and the shieves. The Bridgeport parts guy
I deal with was very adament about not doing that, saying the balance
would be upset, and the old keyway would quickly damage the delrin
bushings as the shives slide up and down the hub. I'm not sure if I
buy that one, especially since he's the one trying to sell me new
parts. Can anyone see anything wrong with cutting new keyways? Is
there a special procedure to press the hub out of the bottom shieve
without galling it?

The other thing I thought of was since I am going to be using a VFD
to drive the motor, maybe it wouldn't be a bad idea to eliminate the
top variable speed components altogether with fixed-size pulleys.
That would seem simpler and quieter. However, I haven't any idea
what would be a good ratio to choose for the pulleys to be able to
get high and low speeds. I don't have a manual for the machine, so I
don't know what the reduction is for the back gear (low speed). Its
also my understanding that torque shouldn't be affected by using the
Mitsubushi VFD's at low speeds--is this true?

Appreciate any help.

Bob