If you end up wanting these cut out in metal... let me know. I've got a 4'x4' CNC Plasma and cut out a bunch of products for others in the norotors and subaru communities.
I spent 3 hours with the angle grinder and $100 drill press this morning. Might take you up on it next time. Pretty sure we've talked before on some other car/bike forums.
Why do you want to increase the size of the pulley? That would just slow down the PS pump. Also, why the front and rear brackets?
Correct, I want to slow down the pump relative to what it would be running with the (4.5-4.6"?) oem Mazda PS pulley on a ls1. I'm running a stock size ls1 damper (7.53") and don't want to run an underdrive damper. The rpm limits listed below are a bit artificial since people bump those up, but the stock damper with mazda pulley scares me a little. There's also flow rates vs rpm and probably a lot of other [something] vs rpm characteristics I don't understand. Originally, I was going to try the mazda pulley but KRC has 4 pulleys that are around $100 that all bolt onto the pump: 6.5"/6" fbody and 6.5"/6" ybody. That was significantly cheaper than some of the aftermarket rotary PS pulleys - most of which I couldn't find dimensions for.
rotary 8043 = 4.625" / 4.6" * 8000 peak rpm
ls1 maz 10803 = 7.53 / 4.6" * 6600
ls1 krc 7646 = 7.53 / 6.5 * 6600
ls1 krc 8283 = 7.53 / 6.0 * 6600
ls1 udp 8135 = 5.67 / 4.6 * 6600
The back bracket adds a bunch of support which is nice since I positioned it about where the stock ls1 pump goes and re-used the ls1 bracket. The pump is sitting on the added bracket which, in turn, bolts into the ls1 oem bracket. That's the reason countersunk bolts were needed. With the pump sitting closer to the middle of the head it's probably not as useful, but then the 6.5" pulley hits the idler pulley. Also, a larger front bracket that bolts directly into the head interferes with the 6.5" pulley. The y-body pulley has some hope of working, too.
I got rid of one the bolts because it was in the way. Still need one longer bolt, maybe some more spacers on one bolt to clear the pulley, reservoir mount, and the pulley (coming next week)before it runs again. Might grab this m14->-6 90 degree fitting tomorrow:
http://parker.com/portal/site/PARKER/menuitem.bb22d5a82bbb5b147cf26710237ad1ca/?vgnextoid=a2d9b5bbec622110VgnVCM10000032a71dacRCRD&vgnextfmt=EN&vgnextpartno=6M14C8OMXS&vgnextdiv=687614&vgnextcatid=2383933&configtype=

