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Yeah, the fancy spokes aren't worth the potential for sheering off said fancy spokes. It ur PS pump is already struggling with a 4" pulley then I'm would tend to agree that might be the limit on size. With PS being a huge load on engines (more then AC or alt), its probably the limiting factor here.
The funny thing about mass is the stock pulley is remarkably light. The under drive pulleys I looked at all were about the same weight despite being substantially smaller in diameter. That's what I was referring to when I said the diameter might already be optimized. Where the next little bit of gain might be realized is with a lighter pulley (titanium for example).
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