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This year my team used aluminum plates. Im not sure what thickness.
For the bearings, use a flanged bearing and collars on the shaft.
What degree of precision? Well, I used a hole saw and hand drill. I really,really dont suggest this. We had many gearbox issues. If you have acess to a CNC mill, use it. And make extras.
I believe DART got all of our gears from WM Berg. I think the gear we got for the chippy motor was a little to small, so we powered up the motor and held a file against it. We then rotabroached a keyway into the gear, and put it on. Use locktite to hold the set screw in.
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