The old VPI pulleys were pressed fit onto the shaft. If you put your motor into a freezer, the metal motor shaft will shrink more than the delrin pulley, therefore, easing up the tension.
Doug, what issues did you have with string drive silk thread and dental floss. Did you spend much time with either of those or was it quickly obvious vs mylar tape?
Years ago when the belt on my Aries broke I replaced it a double strand of 4 lbs test fishing line. I had to change the SDS settings but it runs like a champ. I have a super heavy clamp so I do give it a little push at startup.
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