Aesthetically much nicer made in the Hemingway castings, but I had most of the materials from the works skip during my working life so it was made of what I had in the garage, aluminium and steel.
The only things I had to buy were the ER32 collet, magneto bearings, drive belt and grinding wheels.
Yes you will get more wear in the aluminium than cast iron, and the dust covers are essential, but I expect it will last my life out! The front bar just runs straight in the aluminium end pieces, the centre lower boss has PB sleeves in it but as this is usually clamped to the bar to touch up my milling cutters I doubt it would make much difference if it ran straight on the alloy.
The dust cover is zip tied onto the aluminium (look for the grooved mounts in the photos) and the slots are also filled with RTV to prevent dust / grit ingress that way.
If I had to pay for the materials I would have made it nearer to the Bonelle design, but fabricate lower sections in steel with welded in bosses then machine accordingly.