I'm planning on either using Rulon bearing inserts from McMaster, or just
running the shaft against the aluminum.

Dunno about the adjustable bearing idea -- I've considered it, but if I'm
paying to have it assembled it may be worth a bit of time on a milling
machine to avoid having to find someone who's capable of doing the
bearing adjustment right. The whole bearing adjustment issue is being
driven by the sensor, so I'm going to look into that part independently.

It's important that it look reasonably professional, but bare aluminum
may be good enough -- I may ask for another quote without the anodizing.

--
Tim Wescott


Tim,
I believe there are several expensive areas in your design.
First off, expecting .001" tolerance means it must be milled or wire
EDM.
Can you tell me why the tight tolerance?
Does the mating part have the same tolerance?
What size holes in the mating part?

Next, I don't understand the bracket. Is this a purchased item, or is
it formed into the sheetmetal?
Or, is it to be fab'd separately and attached, if so how?

Material thickness?

Anodize is not a big cost. Here, it's about $50 run charge, plus $1/
part. IIRC.
Dave