tension will pretty much be provided by the weight of the belt itself.
(assuming you go with a reasonably long belt)
You just need enough tension to keep the belt well off the ground and you should be good to go. Don't over do it, more isn't always better.
I'll try to figure out how long the one is that we use - I want to say 25 feet pulley to pulley - but I'll check later.
For width - not super critical for a hammer mill. They tend to clog if you overload them anyways, so slippage isn't a huge concern.
Anything slightly less than the width of the smallest pulley - but more than half.
Try to get the pulleys in line with eachother the best you can, but don't kill yourself. The pulleys have a rounded surface (side to side) that helps keep the belts centered when running, even if you're off a little.
Hammer mills sound like jet engines once they get spinning. You'll love it once you fire it up.
Kind of surprising, the belt looks like it's going slow, but the sound of those hammers flying around will keep you on your toes, being a constant reminder to keep your hands well away from the feed hole.
I don't know what you plan to grind, but unless you want to be blowing it out of your nose for the next three days - get a dust mask!
If it's not obvious - the "hammers" should be reversible - if the leading edge corners of yours are rounded, it'll work better if you flip them and get sharp edges.
I looked, but all I can find is one picture of me grinding corn. Not a very good shot of the mill or the setup. Might have more elsewhere - if I find any I'll post.
Very similar mill - they're all pretty much the same design. If you look closely at the bottom you can see the width of the belt we use.
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Today's Featured Article - Talk of the Town: How to Remove a Broken Bolt - by Staff. Another neat discussion from the Tractor Talk Discussion Forum. The discussion started out with the following post: "I have an aluminum steering gear housing with a bolt broken off in it. The bolt is about a 3/8" x 1 1/2" bolt. I've already drilled the center of the bolt out with about 7/64" drill bit the entire length of the bolt. Only one end of the bolt is visible. I tried to use an easy out but it wasn't budging and I didn't want t
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