Hi Jeff,
I wouldn't try to find the correct F/C pulley, I would try the pulley of a PT or as you used the aircon pulley although I think you might have to lift the motor slightly to get the belt alignment correct. I found an aircon one on ebay yesterday but it was about $30 and the hole needed to be bored a couple of mm. Yes that is what the motors feel like, they won't spin freely as they do with the blade carrier bolted directly. You have to get that big blade carrier spinning and that is where the issue is. I was thinking that with the sidepull it is geared and that might help, but I have also built a couple with the cup pull start and they spun over easily. I'm fairly convinced the problem is somehow related to the PT pull start design even though it is a very clever design, somehow I think it is geared too high for this application.
The pic is the adapter plate that MF will need to bolt an F/C to the base

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Last edited by NormK; 28/12/20 08:18 AM.