+1 for versablocks. Especially for a drivetrain they are certainly your best bet.
AndyMark sells a similar product with one bearing hole:
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Thirding Versablocks, although if they’re out of budget the bearing bore plates will work as well. I think the best way to ensure that the plates are aligned axially is to assemble as much of the drivetrain around them as you can (axles, bearings, chain / belts, and gearboxes) and then match drill the rivet holes through the plate into the tubing. Lots of clamps and extra hands will make this process easier.
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Nearly identical to the Andymark part but half the price (because it’s a 2-pack).
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Thanks so much for the help!
I will go for our own plates first. They seem simple enough to make with my team’s drill press, and there is no shipping and processing time involved (had we had more time, I would probably get the Andymarkhttps://www.chiefdelphi.com/t/bearing-holes-too-big/378586/10?u=thomasart or Vexpro plates (Bearing Holes Too Big))
The versablocks do seem like the best option though. Thanks everyone!
P.S. I just recalled we have the siderails from the KOP chassis. We might as well just cut them to size because the bearing holes are already drilled out.
Indeed.
Mostly wanted to give an extra option if you happened to have a welder handy and didn’t want to wait for shipping on anything.
Yeah, its quiet a neat trick. That will definitely be something to try out, in the off-season. We have a rather limited resource of bearings at the moment 
Fourth+ for VersaBlocks, if you have the space. The two sides will automatically align to each other. The plates will work but you will have to spend time to align each pair
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If you use the bearing block remember to order the cam
Roy
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This might be a long shot, but is the bearing hole actually 1.25" ? If it’s exact then you just need to find a 1.25 OD hex bearing. Much less work and far less redesigning.
Yes, they would probably work best here. I think I will give the plates a try first though.
VersaBlocks+5 are great if you dont have the means to machine those bearing holes!!
VersaBlocks are intended for 2” tubing. On a sheet metal application, they may not work.
I think you’re underestimating just how made-for-FRC-applications these bearings can be. I’m sure someone can make them, but they do not exist in a COTS state best I can tell.
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True that.
If you want to see just how niche these are, McMaster doesn’t have hex bearings smaller than a 11/16" shaft/1.85" OD (and trust me, they’ve got a pretty stinkin’ good selection). Misumi, another supplier I can often find odd items at? Don’t think they have hex bearings at all, and they don’t have all that many in this size range.
There is the old school trick of use a bearing with a .625 or larger ID, buy a bushings with a 1/2" ID and the OD to match the bore of the bearing, pressing the bushings into the bearing and then hex broaching the bushing.
It’s not cheaper and it’s not lighter… But it does make a hex bearing.
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I will be sure to share the result once the team is back at the shop!
Use bearing in both plates with a shaft thru the bearing to align the plates. thread the shaft to clamp it together.
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Alright, I might also use a level and try to keep all wheels perpendicular to the ground while doing that