Without looking carefully, I think it's been more like 21 months since we sold a Kit with the original black molded pullies. We converted when the Squared was released in '07. Yes, you'll want to carefully dress up the flanges, and make sure to glue the sonic-welded flange to the pully.
It's important to get them cleaned up because the belt is not nearly as strong as the plastic, so you'll tear up the belt if you haven't already. Even a single short fiberglass strand protruding from the side of the belt and it's all over -- replace the belt now before it tears up the pullies too.
Build the X - 5 driveline and check it before you assemble the driveshafts and suspension. Run the motor slowly with the bottom cover off and observe the path followed by the belt. Move the idler pulley from side to side by adding small shims between the bushing and idler bar or removing a small amount of material from the bushing until the belt is running perfectly straight and right in the center of all four pullies. This is crucial to long belt and pulley life.
The black pullies will work fine. The machined ones, especially the drive pulley, are better, but you can run the car for a long time with the black pullies. When it's done correctly, the X - 5 will run very fast for many race weekends with no problems. Like anything else, if built sloppily, it won't last long.
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