Originally Posted by 1994ta
Well I'd like a 2.2" pulley either way. A friend of mine is taking a machining class at a nearby university and he offered to make one for me, but we'll see how that goes. It'd take some work to make the keyway an exact fit.. Blue Tounge'* prices are cheaper by about $15, but I'd have to wait and see if they could make a 2.2" also.
The keyway is the easy part. You just need a broach. That'll be by hand, and the rest on the lathe. It would be nice to make one without re-fixturing, but that may make it difficult to get the reverse cut on the back face. You need to get the dimensions CRITICALLY correct on this bugger. The thickness of the pulley, diameter of the opening (use a reamer for the final cut), and the spacing between ribs.