Quote Originally Posted by Boyan Silyavski View Post
I dont know why the worry about the thickness. Let's speak in mm as this Imperial system gives me a headache

If i am not wrong ~ = The bearing has 35mm internal diameter. 22t pulley has ~35mm OD and ~31mm diameter on the tooth lowest point/35- 2x~2mm/ . So if the hole is 27mm that gives a 1 mm clearance from the 25mm ball screw, then (31-27 ) /2 = 4mm wall at the pulley thinnest point, so whats the big deal?
Even so where the tooth is its thicker by 2mm so...???

I was just going by the drawing, which put the thinnest point at 0.0421", or 1.06mm.
It probably would be ok in aluminium, but as I mentioned, by the time you allow for all the forces likely to be acting on the shaft, it is quite a highly stressed part. I wouldn't be comfortable with it unless a FEA showed a good bit of safety margin, but it seems to be a lot of work just to avoid boring out a pulley.