I've been kicking around an idea for awhile to make pulleys from aluminum. I'm a machinist and have access to cnc lathes. I've been thinking about turning some out and using my car as a ginea pig. I feel aluminum would work much better than steel, with it being much lighter and better heat dissipation properties. Right now it's just an idea tho. I have my old plastic pulleys in the shop to use for measurements.