Using Timing Belt Pulleys for full court shooter

[nathan_hui]

One option is to build a set of 0.1255" x 0.4996" bushings. The change in diameter is enough that you can put some tiny set screws in the bushing. Barring that, you can machine a pin to go through it.

Another option is to make a shaft saver similar to what RC hobbyists use to attach propellers directly onto motor shafts, such as http://hobbyking.com/hobbyking/store...col let_.html. Some designs hold the shaft using collets, others use set screws. Both can be built with a lathe and a drill press, or you might be able to find COTS ones that fit your specs.

EDIT: Sorry, not shaft saver. Prop Adapter.

[whophil]

There have been some very good suggestions here already. The best ideas unfortunately require a lathe.

To add one more suggestion, (again if you had access to a lathe) you could turn down the 0.5 inch shaft to a more reasonable size for the pulley sizes you are looking at. You wouldn't want to step down the diameter TOO much as there will be a stress concentration and a potential point of failure at the stepdown. At the torque ranges here it may not matter.

As mentioned before SDP-SI.com has a much bigger pulley selection than McMaster.