At this point I'm just trying to understand the cost drivers for the part
without the holes -- I'll either have the cost to have the holes put in
at a machine shop as a second operation, or I'll see if I can eliminate
the need for such accuracy altogether.


Tim,
I'm a very poor estimater, but::

Initial shearing of the parts is cheap, IF you don't have tight
tolerances. If you are OK with +- 1/8" then things are cheaper than
+- .010". 1/8" can be done on a cheap shear, .010" has to be done on
a laser machine costing $300,000+

Bending tolerance, same issue, looser is cheaper.

A sheetmetal shop cannot hold .001" tolerance on hole position, unless
they have CNC controlled equipment. You are asking for the equivalent
of .05% resistors. Yes, they exist but is it required?
A qualified machine shop will be required if you insist on that
tolerance.
BTW, how are you going to inspect the part to verify the tolerances
have been met?

Dave