the diff is .047 / 2 = .0235, I'm going to give this a shot, using Al, I have plenty of 6061. If it doesn't work, I'll do it thicker, by stepping it so I don't loose strength in the pulley. Tonight, finishing wiring. I ordered bearings from a place that goes by two names, Hard to Find Bearings, and ASAP BEARING. I was having problems finding bearings with a C2 Clearance. Well the quote said ship immediately . They are located in NJ about an hour away. More than a week later I still don't have them, they shipped from CA, and it took 5 days before it shipped, They charged me $15 shipping on 3 bearings.. which way 3.25 oz. I would think that much consititutes faster shipping but it has not hit the East Coast yet. So I won't finish until I have the bearing in hand so I can get my final size, make sure it's the same, and not off by a slight amount. Although bearings are usually tightly spec'd.. but just in case.