I am concerned about the idler pulley causing the belt to come off too, but even with a clutch I must have a way to take up slack in the belt. If I weld this thig together to exactly fit the belt, it may stretch later or I make be 1 inch off etc. I thought it safer to be able to loosen tighten the belt at will. I pretty much got done with the drawing except for the idler pulley assembly if I do that. I found a smaller drive and driven pulley to use (1 3/4" drive and 3" driven) so the lower PVC T in the drawing will hopefully be much smaller than shown. I estimate that this thing is going to weigh in at least 50 lbs with motor (the motor is about 30 lbs I think). I might just start builing this thing and wait and see what it looks like before dealing with the idler/clutch issue.
