I tried to find a larger crank pulley but no one makes one. I looked at trying to get a 460 serp. Pulley but they are hard to come by and all my options require mod ding the new pulley to fit.Sounds to me like your bypass valve was either sticking or not opening previously. That would explain both the noise (feeding back through the blower) and sucking the inlet tubes flat. Looks like you've got it all sorted out now.
I used to have a a 2.5" pully will require a little machining down of the snout....but you could probably just knock it down with a die grinder. Doesn't have to be pretty (especially since the pulley will cover the carnage), just functional.
I actually custom made a 2.35" pulley for mine....sucker really screamed. lol
Try these guys for your needs. It says they go as low as 1.9", but I'm pretty sure 2.5" is the smallest you're able to go. Allen Engine Development High Performance Supercharger Pulleys
Here's the issue....if you get too small with the blower pulley, your belt is going to slip. In which case you've got a couple of alternatives. You can either A) go with a larger crankshaft pulley to increase blower speed, instead of the bower pulley, or B) you can get a wider pulley for added belt traction. FWIW, "A" would be your cheaper bet.
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