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Ideally you want to use "crowned" pulleys (or "belt" pulleys) when driving flat belts. A crowned pulley is convex, which counterintuitively keeps a flat belt centered and prevents it from wandering off the edge. You won't need those curbs at the edges to keep the belt on.
For step 3 why don't you just use a pipe cap? It will be stronger, cheaper, and it will seal itself.Same with step 4. A 3" to 1-1/2" reducer fitting is cheaper and stronger than the handmade wood adapter. And, again, sealing will not be a concern. In fact, it's not clear why you even need a different size pipe. Why not make the whole thing out of a single straight 1-1/2" pipe or a single 3" pipe?Also, you absolutely do not want to put desiccant inside this container. It will have the opposite effect you intend. Rather than keep the container dry it will actually draw moisture into the container. If your seals leak in the rain then a desiccant isn't going to fix that. Unless you intend to check and replace the desiccant weekly then a desiccant is just going to make failure due to moisture occur sooner than without the desiccant.
Many types of stainless steel contain a large percentage of nickel.
This is a trivial detail, but in your description of PVC glue you state that super glue works the same way (by dissolving or melting the base material so that it fuses as one piece when the glue dries). Super glue generally refers to a cyanoacrylate (CA) adhesive. These do not work the same as a solvent based PVC or ABS glue. CA adhesives are initiated by ambient water and polymerize to form acrylic plastic. PVC cements are usually solvents with plastic fillers which dissolve base plastic meterial allowing separate parts to flow into each other before the solvent evaporates and the base plastics harden into a joined piece.tldr: super glue is totally different than PVC cement!
Flathead is a common term for a this type of driver. It doesn't sound at all odd to me. It may be a regional variation for the name. I'm from California. Wikipedia lists flathead as a name variation. Search Google for "flathead screwdriver" and it will know exactly what you are talking about.
You don't need to get the steel up to its melting point in order for it to be dissolved by the aluminum. This can happen with any dissimilar metals when the alloy of those metals has a lower melting point than that of the metal with the higher melting point. The alloy is continuously formed at the interface between the solid metal and the liquid metal. The alloy then melts and flows away from the solid metal leaving exposed fresh metal to be converted into alloy. You can demonstrate this by heating lead or tin until liquid in a copper crucible. Both lead and tin have melting points far lower than copper, but eventually the tin or lead will eat a hole through the copper and pour out. A copper pipe slip cap fitting can be used for the copper crucible. Obviously, do this experiment over a bucket of sand.
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