Thanks Gents.
From the been there done that perspective, I have been thinking about it. This pulley fits right in the middle of size range where the original one was ~2" and the first one I made was just under 4". At 3.25", I think it's going to be ok. I will give it a little more time before I make any significant changes to it, but I will shamelessly try the sandpaper trick if need be.
Right now, I don't think the belts are fighting each other. The AC clutch is not energized and the pulley is free to spin. I will see what happens once it's functional though.
As for the state of charge, when I first started this exercise in Dec, it was low. Still had enough to start though, but I put it on the charger and haven't had an issue since. It starts and runs fine. I have had the low volt issue occasionally if it goes too long between drives, and when I'd give it some gas, the squeal went away. That has not been the experience on this episode.
I will check my clearance though and see if I can make the crank-alt/crank-WP-AC idea work too.
My weekend starts tomorrow and the car is all I have on the agenda until Sat. I hope to make some good progress on it over the next few days and will let you know what happens.
Chris