Not gonna lie, machining that out of AL is gonna be hard and expensive. The endmill alone is $30. The 3/4" aluminum block is gonna be spendy too, $35 a shot for an 8"x8"x3/4" piece of 6061. Then there’s the machine time. This is a multi-operation piece. roughing the outer shape and pocketing the inner circles with a larger endmill, then moving to the smaller one for the teeth. Just gonna be a long time.
Oh, and weight. It’s gonna weigh about two pounds all by itself, which is the opposite direction of where you want to go. - lighter
have you considered those versapulleys? At $6 seems like it would be worth a try before moving on to a super custom part.
to answer the topic tittle, a park deck has tiny wheels cause a low COG is stable, big wheels go over rough terrain better than small wheels but are not more stable on a groomed surface…
Foot fatigue and vibrations are annoying. Though wheels would be one of the last things I would change to counter that. First would be decent skateshoes. There are a lot out there. I love my oldschool high top vans pro model. Good dampers already in. Next step: Get some proper vibration dampening insoles for your shoes. Usually found in specialist trekking stores or in random skateshops. Secondly put 2 brake soles underneath your shoes, prevents destryoing them and dampens it even more, will still give you enough feel (some are crappy and usless and are super slippery). Added bonus you stick on your griptape, mine are just old racing slick tires chopped and sliced then put under my shoes.
If all that isn’t enough try vibration dampening hard foam. Lay it under the griptape. With all that you ride on a cloud even with 82a + wheels.
I love my Gilbert Crockett Pro Mid wish they still made them… I gotta sand the sole even and replace it with a Roger Bros soon… I wish I had put an alternative sole on when they were new so I’d have a perpetual fresh flat mating surface Everytime I needed a new sole
I have a couple nice pairs of skate shoes. I switched those when I first had vibration issues with the hub motors way back when. I specifically want bigger wheels since it’s pothole season and they’re everywhere. Actually I got 2 flat tires on my car on Tuesday… Roads are crappy right now. It happens every year from the Salt and snow.
I come from an online skate/trick skate background. My trick skate wheels were always more similar to skateboard wheels but I could slide/slip easier. Way less grip but I used it to my advantage. My other pair of skates were your typical thin skate wheels but they were way more grippy and smooth riding. They were great at skating rinks or even using them to street skate to the skatepark. I was thinking that would transfer well to the commuter board.
It’s not that it’s that much trouble, it’s that it’s going to create it’s own set of problems. Maybe the ideal solution is the 3D printed pulley, but using steel bolts for clamping instead of those larger 3D printed pins.
It only took around 3 weeks from China too California, so it could be worse. If you really needed one sooner, I might have one that I haven’t used yet.
I was talking to someone about this earlier. Apparently philly doesn’t know how to repair the streets properly. I told her down south doesn’t get snow like we do but she said Canada has great streets and they get more snow. We need to take a lesson from Canada…
Haha yea… south doesn’t get much snow but the roads are being repaved all the time here… NC is the first state I’ve lived in that I actually see road crews working not standing around lol…
Was amazed when I was in Rome and 15cm of snow fell overnight. They were lost, nothing worked lol. Was almost a catastrophy for them. Even trains were cancelled…
Meanwhile we got 1.20m overnight. By morning ebery street was done, salted. Business as usual.
I worked/lived in Filthadelphia for some years. It’s terrible the time of year. Come down south the roads actually get taken care of down here. 
