got it replaced. quick job but pulling the radiator makes a huge mess. PITA.
reason I thought it was on piece of metal was from a cross section I saw on another thread here. looked like all the pulleys were made from the same block of steel. I think the first two are but the AC pulley furthest in is press fit in or something cause it was starting to separate real bad. the grinding noise was the pulley rubbing against the block. made a nasty gash. hope the crank/engine are ok. she runs fine for now.