I have the X and Y axis back together with the aluminum gears now and all the tests show the same or slightly better than the above videos. It has turned out real well. I'll be re-cutting all of the plates now for the stepper mounts so I can CNC the pockets for the bearings and all holes will be CNC accurate. In essence now I'll be able to make the kit.
The pictures show that with the small bearing in the plate and the bronze bushing on the shaft the belt tension pulls the shaft against the outer plate. Hoping the bigger bearings will help with that since they don't have the inner race as a bronze piece. They are one piece ball bearing rather than the roller with the bronze inner race.
Also found that stainless washers are no match for the bearings that where running on them. Have replaced them with the hardened washers.