I got the pulley off today!
Thank you for all the good ideas and, most importantly for stopping me from trying to cut it off - I think I would do much more damage if I tried to cut it.
If anyone is stuck with a stubborn pulley, this is how I did that:
1) I got a new torch Bernzomatic TS8000
I can confirm it runs much hotter than a less expensive torch i used before running from the same MAP bottle. Without a large Oxy - Acetylene setup, which i could not find for rent and is expensive for a one-time job, TS8000 is the next best thing.
do not bother with small Map/Oxy torches running from small bottles - i tried it - the flame is very small and does not heat much.
2) I had a custom plate made which was suggested on this forum. It's 1" thick steel plate with 6 bolt holes and 1 large middle hole for the central push screw.
3) The plate was screwed to the pulley by 6 M10 bolts class 12. Class 8.8 I used just bent. Also, 6 screws vs 2 helped to make more even pull, which probably helped. We tried a smaller plate with only 2 screws and it was getting bent without doing much.
4) I used the largest pulley remover screw I could find. It's 3/4" DIA 8", one from Princess Auto: https://www.princessauto.com/en/8-in...t/PA0008045992
it weighs something like 10LB and is a beast, but it could not do this job on its own without the plate, just broke a piece off the pulley.
6) I put as much tension as I could on the screw and heat the pulley for a few minutes to 150-200C all around
7) I started putting more pressure on the screw with 1/2 ranch and 5' pipe over it while lightly taping with a small hummer around the pulley.
8) worth mentioning that i did several heat/cool/penetrating oil cycles in the last 2 weeks and the last time after warming the pulley i applied 50/50 ATF/Aceton mixture but I'm not sure how effective all of this was because the pulley base goes well inside the cover and the penetrants probably did not even reach the shaft/pulley connection inside and whatever reached from the outside end did not go too far.
I think the faster heating and a huge force of leveraged 5' pipe did the trick but you need the hardware to sustain this force so nothing breaks before the pulley moves.
Thanks, everyone again for the help!