"I wonder what happened to the OP"s belt pulley drive?"
Indeed OP, learned a new shortcut (SC)
I also do wonder how Wheazel's the Pully did work out.
Was its strong enough for this purpose ?
How the flanges on the gear where solved.
(an aluminium rim -bolted trough-on both sides would provide sufficient strength/body I guess)
Overhere Ive modified my HTD pulley a bit and also found that
even the belts have a slight variation in pitch.
Could be caused because its a (China) non brand.
Testing it wit a longer HTD belt proved to work fine.
Now that Ive received a short one wich I am actually gonna use...
the fit of the HTD 5 on the pulley is just a tiny bit to tight.
So slight tooth change and gonna have to cut another pair.