Measuring Pulleys.
You should not be measuring across the tips of the pulley. This is not how a pulley works, the belt does not drive the pulley from the tips.
Pitch diameter. You cant measure this with a standard caliper.
You need an Optical profiler, or a special caliper, or gauge wire… ect…
You could mess with the simpleton measurement chest beat off ratings just by changing the tip radius. Ill put together a picture. while not changing the effective ( real ) radius of the pulley.
What you don’t want to do is stray from the SAE standards of a PK pulley. The specs have min tip radii , and a max groove root diameter to make sure the belt rides perfectly throughout its life.
APR the original pulley, they literally went as small as you could go.
If someone managed a freakin .05mm difference in pitch diameter, then its 1 immaterial, 2 the pulley would be much weaker.
The limit to the size of the pulley is the supercharger’s nose cover diameter where the bearings sit inside.
The supercharger is already being spun well past where it should, and well past the range where diminishing returns from.