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Hello Peter:

You are right, taking cuts from different angles will help a lot. Just because a big lathe could form cut this pulley in one plunge, doesn't mean you must. Lots of lighter cuts are OK.

Just to let you know the risk of pushing your motor to the limit, I pushed my Smithy Granite to mill a welded channel square. Then there was this funny smell and a bit of smoke came out of the motor! It isn't dead yet, but I need to plan on a new motor soon. I'm thinking 3 phase with a variable frequency drive (VFD) so I can have full torque at lower speeds.

Carl.