I haven't really got the time to read all of the post so just quickly flicked through the images but I can see straight away that you are going to run into trouble with alignment and setup because you haven't got any adjustment so even with a machine to help you make parts you won't make them so accurate that you won't need some way to make adjustments.

The golden rule of DIY building is to allow for Adjustment, then a little more adjustment for good measure.