Here is a progress update on the silent pulley downgearing system I came up with using thumb tacks and a #2 fishing crimp sleeve and little plastic discs. It is some tiny fine precision necessary work but I'm getting it done and things seem to be looking pretty good so far.

For now, I ended up just using 401 glue to glue the thumb tacks down onto post it note paper. I then put another coat of the glue over the tops of the thumb tack heads to secure it further. I am planning to use nylon upholstery thread lashings to lash all the tacks down onto the top of the 2430 bldc motor tightly and glue the lashings down as well in order to make the thumbtacks even more solidly set into place. Now I'll grant welding them down would be ideal, however, not having a micro tig welder made yet (future project), I just wanted to get going fast and I thought with enough care, it is possible these can be constructed solidly enough with composite material techniques to function reliably. I'm crossing my fingers. We'll see.