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A metal rim fixed to an interchangeable hub, perhaps 3D printed, might be a good blend of options. The metal rim would be in contact with the belt so would see the most heat and hold up to the friction there better, while the hub could be designed with a reinforced structure to better resist twisting forces. The water pump is directional so the pulley hub could be made very strong in one direction without concern for its strength in the opposite direction. This also simplifies the matter of diameter, as a large diameter, thick wall piece of say, aluminum driveshaft from the junkyard, or other scrap, could be turned on a lathe to whatever diameter you like, maybe even incrementally.
For that matter, the OE pulley, usually stamped steel with a machined center bore, could be turned INTO a hub just by parting off its rim on a lathe then attached to a separate rim of whatever other diameter would fit. Perhaps find a pulley of the correct outer diameter and take it with your original pulley (or a spare from the junkyard) and have the rim turned off yours, the hub removed from the other, and the two combined by welding or bolting through the resulting flanges. An interference fit here would be very easy to achieve without fasteners but I'd want things at least tacked to withstand vibration. This is how these things were done before there was an automotive aftermarket.
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