2010/8/20 Ian W. Wright <[email protected]>:
> I'm not too sure whether my problem is play in the bearings (they seem
> tight enough) or bending of the rods.

I am sure that it is the bending of the rods. At least it was the
cause for the similar case that I know of.
Why don't You use more rigid structure - something like these profiles
+ supported slides?
http://www.worldofcnc.com/products.asp?recnumber=81

That way the construction would be much stronger, and I think that
existing structure of the router would require only minor adjustments.

Viesturs

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