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There are a few concepts and definitions in this thread that in my mind make the discussion a bit clouded, as it often does when it comes up.

Hope I can point all of it out, here it goes.

First...

Provided you can find brushes of a similar hardness and compound it's entirely acceptable to file or machine oversize brushes down to your required size,
Regards,
Nick

Dave, have you looked at the WARCO, Amadeal, Grizzly and other Chinese made mills as I'm sure that they all come out of the same factory? I bet one is similar to yours and will use the same motor.

When you say 9.64V at 100% you have entered 24000 rpm as the spindle speed in Mach havent you.? . . .. 100% is of the commanded speed not your VFD.!!

Try tweaking the pulley speeds and you should...

What Voltage are you feeding the BOB with? ..Clive