[ericzundel]

More from the Team 1379 First Overdrive robot experience. We had one square section of aluminum permanently embedded in another. Everyone laughed when I tried to take it out one day.

We machined blocks of Delrin as sliders, but the tolerances were still very tight even with liberal amounts of grease and had to be re-machined a couple of times if I remember correctly. I wouldn't dismiss the 80/20 linear sliding solutions so quickly. Besides the bearings, they have pre-engineered rollers or you could make your own to fit in those slots.