Stopped by Ace's today to pick up some parts for the machine. The best option i found for a linear bearing system was to use sliding door rollers and aluminum C channel. Here are the door rollers screwed into the sides of the Y chassis.
Here is the completed Y chassis framework: I'm still not sure how exactly I'll mount the Z chassis, but the general shape is there, and the chassis moves fairly well in the aluminum channels. It rolls very well even under large weight, so I think it'll do fine. The rollers aren't perfectly perpendicular, but the linear screws on either side should suffice to keep the chassis steady.
A closeup of the window roller in its C channel housing.
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