How can I make or buy a simple timing belt tensioner? I've tried a fixed-position idler pully, (like where my finger is in the picture) but it put too much tension on the belt, and the motor struggled. If I tension it with my finger, as shown, it works great under load. Is there a spring solution that would put about 10 lbs of tension on the belt? The belt is 6mm wide, and the pulleys here have a 60-to-20 tooth ratio.
Thanks for any advice.
Sounds like idler was incorrectly mounted and placed. It should be on a track that allows tension to be adjusted from zero to maximum.
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If you can rebuild your stick, you might be able to move the hole up a bit and rotate the motor within the hole to set the tension.