I know I'm a little late to the party at this point, but I have a couple 3d printers I can put to work. I'd love to help out if this is still an active project that people are interested in.
I had my tensioner pulley take a shit on me too around 50k, it froze up and the belt shredded leaving me stranded on the highway, fun times lol...
Edit: I did replace mine with the gates brand tensioner, because cheaper and why not?
I had the clips break off on two of my AP cables so far, but I just emailed Cobb and they sent a new one out at no cost to me.
I generally just leave my AP in the windshield suction mount I got from Amazon, when I park the car (unless I'm in a particularly shifty area). With my tints and where...