Well I got a pile of 6mm aluminium plate cut up along with a heap of MDF on a friends table saw. I used the principal that aluminium is softer than some hardwoods, so the table saw should cut it just fine. This was the case. The plan is to make each part from MDF first to make sure everything is ok and then proceed to the aluminium. For the rails I have decided to use flat cold rolled steel with bearings running on the flat surfaces. The 2 top bearings will be on plain straight shafts and the 2 bottom ones will be on cams so that they can be adjusted to allow for inconsistencies in the flat bar and or workmanship. The 2 bearings on the side will have plain shafts on one side of the gantry and cams on the other side. This will allow adjustment sideways also. I will require 6 bearings per slide and there will be 4 slides of this type on the machine. This will result in 12 plain bearing shafts and 12 cams. I guess I will learn how to use my new lathe better by the end of this project. That’s it for now.