I think my old thread ran its course... I finally went ahead and got something I had designed rapid prototyped. I found a place that did the work for very cheap and while the results are less than stellar, its workable. Getting these done in a high resolution is much much more expensive, on the order of 20-30 times more. Also in the picture, you can see the same part I made from styrene. This was my original attempt and I didn't care for the qualtity I was getting out of my work, so I just went back to the computer and started designing all my parts in Solidworks. The styrene shows details better, but the RP part is more consistant in terms of symmetry and is much more rigid. The surface is rough, but can be sanded down. My final build may be a combination of the two or I'll keep looking for an affordable source to do a high resolution part. The part was made for $18 shipped. I would get a better deal if I made more. Some answers about the pictures: 1. Yes, its what you think it is. 2. I have spent MANY hours on this project... however... 3. I'm not ready to start a WIP thread until I know I can finish him, its getting close though. I would put him at 70% designed. 4. The other picture is a snapshot of what I made in Solidworks. 5. The funky window on the styrene piece is not supposed to be there, I messed up that end. The RP part has one at the end not shown where the "eye" would be.