Thanks guys
The bearing blocks were made using the following process:
First, I drilled all the holes using a drill press (as you can see in the first picture). Next I removed the semi-circle shaped chunk of aluminium using a hacksaw and a pair of pliers. Then, using a tungston carbide cutter (the one installed in the dremel) I removed the spikey chunks of aluminium left behind from the previous step. Then, I rounded off the edges using the file with the curved surface and the stone cutter. Finally, I used the sanding/polishing bit with some wd-40 sprayed on it to achieve a nice smooth surface for the bearing to sit on.
The other, flat file is the one I used to get a nice flat edge on all the parts.
Also, the drill bit I have been using is a double sided pop-rivet bit, and is by far the most durable drill bit I have ever used...the sharp angle at which the tip of the bit has been cut makes it very accurate too
