as already mentioned de burr edges and try without the key fitted, also give the crank a good buff off with wet and dry and a bit of wd 40, crap can build up on here over the years and affect the fit, then look at polishing the inside of the gear, and check the fit of the woodruff key and ease the fit iff needed with a needle file.
If it nearly goes on then a little bit of heat is ok, but we are talking warm it up to say 100-150 degrees in an oven, NOT hitting it with the blow torch! also bear in mind that you have to get it in place before it cools, and also there are the oil seals to consider. they should be pretty heat proof but...
on the subject of belts and them being replaced by chains, thats all very well but this has mostly happened with the introduction of other vibration absorbtion tech, such as DMF's, and also most variable cam timing pullys work via fluid so are very good at absorbing harmonics. the car engins IMO is a very good application for a belt generally, assuming the service life is observed. also lets not forget chains can cause issues too, just look at BMW's early N47 engine, lots of chain issues there, (although to be fair thats down to the sprocket) and where did they put the chain! next to the flywheel! Silly BMW!