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I checked dimensions as you suggested, and when I installed the pulley, everything got sucked up tight.

No. Wanted to make sure it would spin without issue before I completed the repairs (ie. installing pulley and soldering wires).

I'm currently replacing the front end on one generator (broken attachment ear) and rebuilding another (attachment ears broken on both ends and replacing the rotor, as well as bearings, seals, etc.). On the one I'm rebuilding, I have it assembled, but the rotor is too far back and the aft vanes...