On 21 Jun 2005 18:07:02 -0700, wrote:

I don't rock. But pulleys do. It's rare for the amount of
cable-travel to exceed more than 90 degrees of rotation of a large
pulley. That means you don't really need sealed ball bearings; a
properly fitted bushing (Grangers, McMasters-Carr, etc) works fine.

After making a few I took the trouble to grind a tool bit for the
groove & shoulders.

Bob, one of the more interesting manufacturing processes I have seen
involves making pulleys by slitting the edge of a piece of sheet
metal, then rolling it out to make the flat/vee/round depending on the
"belt" planned.

This was 10+ years ago; I wish I remember whare I was. IIRC, these
were for alternators and water pumps.