Quote Originally Posted by Robin Hewitt View Post
Wonder if I could turn a 5.08mm pitch pulley down a tadge. The 5mm tooth seems a pretty good fit in that.
24t * .08mm / Pi = 0.61mm off the diameter. Might work. Or am I completely getting the sum wrong?
It is not that simple to get the pulley tooth size. You have the pitch line, which corresponds to the belt insertion, where the belt bends. From there you calculate the gap between the teeth to correspond to the belt teeth dimension. The teeth on a smaller diameter pulley are narrower than those on a bigger diameter...

If you tension enough the belt you'll have no backlash even with a smooth belt. The teeth are there for timing ... at times