So I’ve been wanting to build the Gingery series of metal working tools, starting with the lathe. As part of that, I’d need some v-belt pulleys. I could buy them, but that seems a bit expensive.
Why buy, when you can build?
So I built a jig for cutting the v-groove and and it’s turned out pretty good.
The inside angle of is 40 degree, so the jig hold the material at 110 degree relative to the table, giving the required 20 degrees on either side.
Operation is just like cutting a circle on the tablesaw, but with a different angle.
When I attach the pulley to the shaft, note that I’ve drilled and tapped a hole. I have a 1″ 1/4-20 screw on either side. One of them is visible and the other is hidden. 
Cutting v-belt pulleys on a tablesaw
Hey what a great Idea. I need some large pulleys for a band saw I want to make. This will really help Thanks wWarren
It’s been awhile since we’ve seen any action on this blog… I’m worried you might have lost some digits on your last table saw project and can’t type to let us know.