"bz" wrote in message
98.139...

and add a spring?

The current idler is physically limited in its travel, adding a spring
there would not help unless I put a longer rod AND cut a hole in the case
for the belt and idler to travel through!!!

Yep, it's a pain. Keep a look out on http://freecycle.org/ or
http://www.craigslist.org/ -- maybe someone has a busted one with a good
belt.