MVHPV.

The reason I posted the file produced by CamBam is because I believe it will allow you to easily produce pulleys for use with timing belts that are commonly available.

If the CAD drawing was only intended to represent the basic form of the pulleys I was going to suggest that you don't go to too much trouble in getting an exact shape. Conversely, if the drawing were to be sent to a CAM system for manufacture, it would need to be accurate.

BurrMan

That would remove some but not all of the material in that area, a little would remain on each curved section near the root.

Martin.