[Retired Starman]

An easy way is to get a bronze bushing with the correct inner and outer diameters and length, and press it into the pulley. Next redrill the set screw hole and tap it all the way through the bushing. If the motor shaft is really small, like 1/8 in., you might want to drill all the way through and install two set screws. I'd also use Lock-Tite to keep the set screws in. The neat thing about this method is that the bushings are quite precise and will center your shaft in the pulley.

McMaster Carr, and others, have these listed, I think, under "bronze bearings".

As mentioned above, watch for other potential problems.

Dr. Bob

Chairman's Award is not about building the robot. Every team builds a robot.