I got the replacement pulley that I cast yesterday rough machined today. I made the largest pulley a little bigger than before to get my lowest rpms even lower and I left the unimportant surfaces as cast rather than taking meat off to pretty them up and weaken the part.

I wish I had tried mandrels and expanding collets long ago because they're working great to turn these parts with features that need to remain concentric to the bore. I've known about them for a long time and just never got around to trying them and now that I have I see the potential for improved machining.

I Didn't Like the Pulleys on My Drill Press-new-pulley-roughed.jpg