Well, I got totally off target this weekend. I posted a week or so ago about my belt slipping on my Daily Driver and the end result of that was when I converted it from chain drive to belt drive I got the wrong belts. I got HTD 3M where I needed HTD 5M.
So that meant replacing both the motor pulleys, the wheel pulleys and the belts. the Daily Driver runs 6-shooters and I had been complaining about the fact that I didn’t quite have enough hill climbing power and slightly too much top speed, so this was an opportunity to change my ratio a bit. I wanted to go to 4.4:1 from what I have now which is 4:1, but running 3M belts. With the new battery pack going in I’ll be able to bump up the battery current too - probably an additional 10A will do the trick
So I needed a 66T and a 15T. The 15 wasn’t a problem, you can get those at any esk8 shop, but without spending a horrendous amount of money you can’t get a 66T. So I had to make one.
Now I’ve made chain cogs before, but I’d not made pulleys. Turns out they are almost exactly the same. I grabbed a CAD file for a 60T off SDP-SI and modified it a bit to make it 66T, then I had to order a special cutter because all the ones I had that were a usable diameter weren’t long enough to cut the depth I needed.
Then the Delrin that I had in stock turned out to be 3/8" and not 1/2" as I thought it was, so I had to make each one twice (which actually works out better since I need to be thicker than 15mm, which is ~0.59"
Anyway, here it all is:
The grey things are what was originally going to be the edges of the pulley when I thought my Delrin was 1/2", they would extend the thickness just a little bit, like this:
but I won’t use them.
The 4 in the center are the 66T’s and the two on the right are 15T’s. I figured I’d make a few for testing since once you have the tooth profile it’s easy to make them in any size you want, you just have to math out what the OD of the pulley is and then attach the right number of teeth to it.
Here’s a picture of the mill cutting the 15T’s
Now I wait for the belts 
I did get a little bit of work on the control box (electronics housing). When I have that baked I’ll talk a lot more about it.