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Mechanical reference

Belt Length Calculator

Turn two pulley diameters and their center distance into the belt length you need to order.

Short answerL = 2C + (π ÷ 2)(D + d) + (D − d)² ÷ (4C) for an open (non-crossed) two-pulley drive, where C is center distance and D, d the pulley diameters.

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How it's calculated

The belt wraps each pulley by a half-circle plus a correction for the size difference, joined by two straight spans equal to the center distance. The formula sums the straight lengths, the average wrap, and a small term for the diameter difference. Use consistent units throughout.

L = 2C + (π ÷ 2)(D + d) + (D − d)² ÷ (4C) C = center distance · D, d = pulley diameters
Worked example
  1. D = 10 in, d = 4 in, C = 20 in.
  2. L = 40 + 21.99 + 0.45 = 62.4 in.

Reference tables

Belt length terms

TermMeaning
2Cthe two straight spans
(π/2)(D+d)average wrap around both pulleys
(D−d)²/(4C)correction for pulley size difference

A number the tables do not give: with 10-inch and 4-inch pulleys 20 inches apart, order a belt near 62.4 inches and adjust to the nearest stock size.

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FAQ

Open or crossed belt?

This is the open (same-direction) drive. A crossed belt uses + instead of − in the size term and runs the pulleys in opposite directions.

Do I need extra for tension?

Round to the nearest standard belt and rely on the drive’s take-up (adjustable center distance or idler) for tension.

Diameter — pitch or outside?

Use the pitch diameter for V-belts and timing belts; the pitch line is where the effective length is measured.

More than two pulleys?

A serpentine or multi-pulley layout is summed span-by-span with wrap angles per pulley — this formula covers the common two-pulley case.

This page is a reference aid. Always verify against the drive and belt manufacturer data. Figures shown are for orientation, not a stamped design.

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