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@domco: the geared pulley you worked will be fine, but the belt will run pretty close to the ends of the extrusion. I used my "minified" universal plate with the belt, and looped it over the top instead of from the bottom, which added a bit of a sloped look to the belt and it looks funny. I'd recommed running the belt underneath the plate so it runs perpendicular to the extrusion. The only reason why I went the other way was to get the teeth on the belt to engage so that when I ziptie it together, I'm positive it won't slip. I can post pictures of my assembly if this doesn't make sense. That said, I'd love to see pulleys with a larger OD so the belt doesn't run against the extrusion.