Why don’t you try using a simple hand held hole puncher on some plastic sheeting ?
I think it’s about the right size for the pulley. The punches come in different sizes.
As long as they’re round it will work.
You can use a smaller diameter punch to make the inner portion of the pulley, and the larger one to make the outer groove part of the wheel.
Stack them. Large , small, large. Add a touch of plastic glue. Presto you have a pulley. Add two more, (one small one and another larger one) round bits of plastic that you punched out from the sheeting and then you will have a double groove pulley.
If you really want to get creative with this you can use a thinner sheet of plastic to make the outer edges of the pulley, leaving the center groove thick for the rope. By using the punch set, all of the pulleys will be of the same size.
This took me longer to photograph and post than it did to build. I was a bit sloppy with the alignment but I just made this set quickly as a training aid.
With a little sanding this set will look fairly good, and even better once you string in the miniature rope. Since it’s plastic it will be easy to drill out the center of the pulley if you want to make it a working wheel.
I personally think that once these are painted and rope installed, they will look very close to what you want. You can sand down the outer edge a little bit if you think the diameter is too big. This is easy to make and it gives you plenty of options.
Here I placed an Exacto knife next to the pulley set to use as an easy reference for size. This one appears to be close to what you have made.
It’s great to see the good Doctor having fun.
Your “Orca” is getting to the point where it’s the little details that will set yours apart from the others.
It’s looking great my friend. The mast and the navigation lights are spot on.
1 additional image. Click to enlarge.
