correct. you'd need your bearing hole and your outside layer of aluminum would need a SMALLER (you said larger) hole so the bearing couldn't pop out.

Ops well yeah I meant a smaller. :P Thanks. That would be easier to do with just a thin layer of alu. Wouldn't be that hard to make a somewhat thick layer with bearing sized hole, and another thin layer of alu with a smaller hole and just screw it onto the larger layer.

that would do it. definitely a way to get around not having the right tools. good thinking!

It may be a little difficult to achieve a perfectly round hole with a drill bit though. You'll want to use a center punch and several smaller drill bits working your way up to the final hole size.

What tools are usually used for such work? Got a link to a setup?

Boring head with a set of boring bars.

http://ttv.mit.edu/tags/331-to/video...machine-shop-7

A boring head is about $60 and a set of bars is $20 or so.

This is usually used on a mill, but can also be used on a drill press. With this, you could use just one piece of aluminum since you can control the dept of the hole. This is what I plan on using.

Will do that.

By the way, do you know of some metal cutting/types of metal tutorials? A tutorial on metal or something. Basically I would like to know more about how to work with metal, and cheap tools (Tools not ranging in the 10.000$++ range.)

That MIT video series is very good for that. Takes a few hours to get through all of them. As for tool, I just ask a lot of questions at the metal working forums. CNCzone is one I've been spending a lot of time lately.