The metal cutting bandsaw conversion is officially complete. Decided it would be easier to just buy the correct blade rather than dick around trying to weld my own. I'll still try that for the experience, but at least I can cut metal while I'm experimenting.
Original driven pulley was 12" and that was TOO slow. Ordered a 6" off McMaster and a suitable belt and that seems to be about the right compromise between cutting speed and heat.
Motor is adjustable left/right and forward/backward to align the belt to the gear reduction. Gearbox is adjustable in both planes as well to align the belt with the driven pulley.
Bronze blade guides came out well. Only thing left is to try and find a new upper wheel to replace the one that's been brazed back together and flops around like a wounded duck. With new tires on the wheels and a the proper tension, the blade DOES stay on the wheel, so it could be worse.