the biggest problem is the machine is built already and space is limited. if i could do any kind of reduction it would probably have to hang out to the side but if i could come up with a way now i know i can put whatever size on the open loop side and increase the circumference to get more engagement. i think the belt is compressing under load with a tiny 24 tooth pulley. so if it is doing it on the open loop belt side a bigger set on the other side would be a good idea too i think if it's even possible my fear is i painted myself into a corner
i will have to dig some more and look at the stuff you suggested in more depth thanks for the feedback
straight cuts work just fine but cutting a contour is where things get weird shows up looking like chatter when trying to finish. it is so close to being there but needs a little help to get that little extra bit of stiffness needed