Just glue the pulley together. Use a scalpel to scrape the teeth off one end and the backing off the other (there are some fine steel wires in the middle, take care not to cut them), then overlap the ends and glue them. Do not use a cyanoacrylate glue ("super glue"), it will be too stiff. Get a natural rubber or neoprene-based glue, they're used in shoe repair and very effective at making flexible joints.
As for the pulleys - mould them, really. You can use an epoxy glue, readily available at any hardware store. There are some epoxies advertised as "liquid metal" etc., they're expecially good for this.
Oh, and you don't need a reprapped mould, just get a piece of wood and drill it with a 5/8" or so spade drill to the depth equal to your preferred pulley height, then drill a through hole in the center for the shaft, with a 1/4" metal drill (a brad drill would wander too much in the hole created by the spade drill's pilot point).
