you could use something like solidworks to model this. but if you've never used CAD programs you'll probably need about 50-100 hours practice to be able to model something like a pulley. Alignment is crucial so you'll also need accurate measuring devices (vernier calipers etc) to get correct distances.
you may be better off contacting an engineering company such as http://www.kilner.com.au/. give them the pulley and say I want this in aluminum with a new diameter of X. mm.
also be prepared to pay dearly. A lot of engineering manufactures have a minimum dollar value per job, and as its a one off item they cant make any decent money on it and will try charge you the earth. call around
on my previous car I replaced the cat and decided I would fit it myself to get some practice welding exhaust pipe. as there was a temp sensor just after the cat I needed a bung. both the bung and flanges were done in solidworks.
I turned the bung on my dads lathe and had the flanges laser cut. just an example and a pulley would be a lot more complex than this small project
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