Soooooooooooo,
Download a correct XL pulley off the web as a CAD file, sort out some sizes and play with the figures and get this.

Generate this, save as dxf and compare it to the original file.

Purple is the original file, green is Gearotic and by the time you have knocked the edges off with a scotchbrite wheel is will be the same.
So all you have to do is note the setting
[EDIT] Thickness fits better at 0.62, not 0.64
And then any XL pulley can be cut.
John S.