I have done just over 5k miles in my car and have always kept the belt tensioned to 15mm deflection and the belt set to run on the edge of the sprocket, giving about 3mm clearance between belt and tyre. The belt would however rub on the tyre now and again when accelerating and the sprocket is also wearing away but not to the point that it can be replaced under warrantee.

Inspired by Calum's post I decided to see if I could modify the hub to align the sprocket better, and avoid the drive belt overhanging the sprocket or it rubbing on the tyre. Also since new I have had an annoying scraping noise from the drum brake which was quiet loud when moving slowly which I needed to investigate.

Checking out the position of the wheel, sprocket and belt, the hub required 5mm off of its wheel flange, to move the wheel away from the drive sprocket and create a couple of mm clearance between the belt and the tire when the belt was running against the thin flange on the sprocket.

The wheel's flange on the hub is 20mm thick, 5mm was turned off by a local firm for £30. The reduce thickness looks ok to me and should easily cope with the stresses imposed on this part. (A seasoned engineers opinion that is)

The grinding noise was found to be one of the return springs of the brake shoes, catching the cap head screws within the brake drum, this was bent out of the way.

The belt now sits in the center of the sprocket’s face and if it moves across this face is kept off of the tyre by the sprocket’s flange.

I have done over 200 miles since the mod and it has made a significant difference, no more scraping between belt and tyre and no more grinding when going slow. It is better than new, Brilliant. All I need now is a steel sprocket to replace the worn aluminium one which I hope I can negotiate a good price for when the chassis kit is fitted to strengthen the front end.

Here are some photos, can't get them to show in this post...
[img:center]http://i448.photobucket.com/albums/qq205...p;1438705952371[/img] [img:center]http://i448.photobucket.com/albums/qq205...p;1438705952371[/img] [img:center]http://i448.photobucket.com/albums/qq205/talkmorgan/IMG_3764_zpsr6klrqhf.jpg?t=1438620488[/img]