Here's what I did.
I turned a small post to fit the original ID of the pulley then put the pulley on that and held it in place with a bolt and a large washer. I then skim cut the OD of the thin flanges true and to a common diameter (I had more than just one pulley to do).
Then I took a small length of aluminum tubing or pipe and bored it so that the flanges fit snuggly and against a shoulder. I drilled and tapped three screws on the tubing for clamp screws which fit in the root of the pulley's notch. I then used small pieces of aluminum welding wire between the clamp screws and the pulley and snugged it in place and bored the ID.
:wave:
Scott
Consistency is a good thing....unless you're consistently an idiot.