I think you are on the right track. Weight farthest from the center stores the most energy so grooving any smooth pulley is probably a good idea. My new Al WP pulley is pretty thick but I am concerned if I make it thinner it could crack. If this is anything but the harmonic damper (sounds like you are talking about a regular pulley) I would not worry about any additional harmonics. Definitely would not add weight. Any balancing would happen with a grinder or hopefully more sophisticated machine,
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Originally Posted by serialk11r
I am not sure how much machine shop time costs, but an idea I had was machining stock pulley grooves to reduce the diameter and then adding mass to the pulley to restore its original harmonic damping.
You can also lightweight it at the same time by machining out the center, which usually has a lot of excess steel.
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