Ok, so I went and bought another pillow block from Northern Tool ($12). I had some more scrap steel laying around and built a third support for the 1" shaft (giggidy). Once I did this the wobble went away and it ran much truer. Next, I aligned the pulleys, which required twisting the engine slightly. No biggie, that shit was built in. Lastly, I put the idler back in the mix. More scrap steel and using the idea of a square Toyota drives haft I had something cooking. I also included a fine thread bolt for pulling up on the idler. I found that the idler just needed to take up slack. If there was any pressure, the engine wasn't happy.
At this point, I was ready for round two. This time it was glorious. I did the whole front lawn and the back without any issues. I also learned that running the engine WAO was not the trick. Just under full throttle netted the beat results. It had plenty of air flow. Enough that I disconnected the hose from the mower and walked around sucking up big piles of leaves effortlessly.
Here's a picture of my neighbor coming by to check out my handy work. His comment was, "yeah, i can tell this was some of your engineering when I saw it"
Touche Dallas, touched.
Two things need improvement. First, I'm blowing so much air into the box that any cracks are outlets for leaves. I've got to seal it up better. Secondly, the hitch is strong but because I used triangulation, I've cut my turning radius to shit. This includes backing up too. Oh and number three, the hose attachment is horseshit. Making it out of HVAC ductwork was not smart. I need something more substantial. I'm thinking black stovepipe. I also wish I had some real vac hose. This corrugated stuff wasn't bad but it's really stiff and doesn't bend easy.
Meh, not too shabby in my mind. I saved a couple hundred bucks making my own and learned a few things. I also got a sweet welders tan from it, which reminds me I'm in the market for a good welding jacket. Any suggestions?