Fu**ing crank pully
#27
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This is an Interference Fit. The first time that thing spun off you were in trouble. It sounds like the crank snout was "sanded down" more than just a "bit". I sure wouldn't sand the crank snout and if I did it would be 600 grit or higher and I wouldn't put any elbow grease into it. The primary function of the bolt in not to keep the pulley from spinning on the crank snout(That's the job of the Interference Fit), but to keep it from Walking to New Orleans to quote Fats Domino. If you're FI you should have already been pinned. It appears there is no interference between the crank snout and the pulley hub at this point so the pin may be only a band aid sorry to say. There will probably be more bleeding down the road unless you get real lucky and if you do play the Powerball.
#29
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I think basically to fix it the right way you need to replace the crank. Too much material has been removed from the snout of the crank, and even though you pin it, the pulley could still be wobbling and walking on the crank snout, eventually it will wear down too far and something will give.