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You have two problems.

1) You didn't bore the centers accurately. Easy fix is to get it done on a lathe.

2) While you can make it work without flanges it's certainly the harder way to do it....

You pretty much *need* a lathe to bore the pulleys out properly. I was in the same situation you are with just a mill. I used a coaxial indicator to dial in the exact center and then a boring head to...

Looking at the wiring diagram here starting on page 14 (http://cnc4pc.com/Tech_Docs/C10R10_USER_MANUAL_V2.pdf) You connect the signal wire to the BOB with a 10k resistor (if using 12v). The switches...

PNP or NPN are the collector types of the transistors that make up the switch. One is current sourcing, the other is sinking. You can read about it on google. I checked the manual for the C10 BOB and...

I have been pretty happy with these proximity switches from ebay (SN04-P2 DC 3-Wire PNP NC 5mm Detecting Distance Proximity Switch 10-30V) They take 10-30vdc and hook up great to my Mesa 7i76 in...

I don't have any pointers but I'm at the same spot you are, finished with the mill, have a G0602 to convert. The BD tools kit looks nice. The pictures on ebay make it look like he's using the stock...

I use FS Wizard too and it does a good job. You can set the max rpm to whatever your machine can do. The only recommendation I have, as a newbie as well, is if you don't have flood coolant and you're...

I was all worried about mine because I can see the tooling marks too. I ran my fingernail over them and they are certainly not like a file. My nail doesn't catch at all. They aren't smooth like glass...