Idler pulley issues

Both of the idler pulleys that came with my Island failed, were replaced, and now the new ones have failed. The edges of the pulley are missing or bent downward to the outside. They look like the cable went over the edge, bent the edges down, and now the cable slides right off of the pulley.

Two questions;
1. Does anyone make a stainless steel version of this pulley so I can avoid this issue entirely?
2. Assuming this is my issue rather than a design flaw, am I over-tightening or under-tightening the idler cable?

Must be a problem with how it or the pulleys are being installed. Can you give up a picture?

_________________
Greg

2016 AI - Spinn & Jib

“Out of sight of land the sailor feels safe. It is the beach that worries him.”
– Charles G. Davis

There was an issue with the wall thickness of idlers at some point. Maybe replaced with the older version?

_________________
Matt Miller
Former - Director of Parts and Accessory Sales
Warranty and Technical Support
Hobie Cat USA
(Retired 11/7/2022)