I just installed my "new design" waterpump pulley tonight and ran into an issue. The new pulley is smaller AND about 3 times thicker than the old paper thin design and I thought nothing of it on install. Everything bolted in place nice, the belt went on nice and I left the fan assy. out as usual for initial start up(just in case there's a problem). Once I fired it up I heard an odd noise and looked at the pulleys to see that the new WP pulley was NOT SPINNING. I quickly ran an turned the engine off and got to see my nice belt smoking and the "seized" pulley. After it cooled off I removed the belt again and could not turn the pulley by hand. I then unbolted it and saw the near completely burned off paint/coating where the belt was rubbing across and then on the inside edge I saw a gouge/scratch which was an indicator of it hitting something in back. I then traced the problem to the waterpump housing which has two spots that were stopping it from turning. Luckily I have a LOT of tools at home and happen to have a aluminum burr and grinder to grind off enough of the WP housing to clear the pulley and now it spins freely without issues. I don't know how many others have this new design pulley OR if they have had similar issues but I felt it should be thrown out here for future reference.
Here's some pics of what went down................
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