Making timing pulley - putting theory into action

[Jonathan]

I have only done XL series pulleys, so trapezoidal not round. Looks like it's easier to get it right with HTD. Should start replacing mine on the router.

JohnS' makes mine look a bit amateur:





As those went on my router they've had a lot of use and the pulleys under where the belt runs has got polished. Same is true for the bought ones. I wonder if it's worth anodising them to harden the surface? Would have to be careful not to change the dimensions too much in the process.