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Download some of the gearboxes from the White Papers. Besides drawings, most give fabrication and assembly tips.
As for your questions:
A) We use 1/4" aluminum but have used 1/4" and 3/8" lexan (polycarbonate) in the past.
B) I like to use flanged bearings with flange to the inside. This traps the bearing without the need to glue. Motion Industries found some at reasonable prices.
C) Hole sizes are detailed for press fit. The nominal size with pin punch method has also been used when a boring head is not available. All our work is done on a manual mill.
D) We also custom bored and keyed a standard gear for the CIM. I gave a toolmaker the parts and he shimmed a standard bushing and broach for this.
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