I have designed three alternatives.
They all use bearings that I know I can get, rather than bizarre exotica.
The first idea is:
https://picasaweb.google.com/lh/photo/EqgIdXH-kCH8I90oYKfm2dMTjNZETYmyPJy0liipFm0?feat=directlink
This actually uses a car wheel bearing, which is angular-contact and
has adjustable preload.
The preload is adjusted by the orange threaded collar. The pulley
screws on and in doing so it clamps the outer race. Clearly some means
is needed to stop it unscrewing again.
I am not sure I have the available length for this design, though.

The next alternative is more conventional, and uses a double-row
angular-contact bearing (3809). This bearing is not adjustable, and
looks like it would be a lot less stiff than the first one.
https://picasaweb.google.com/lh/photo/DELJ44ystXfa1HavUrYFmtMTjNZETYmyPJy0liipFm0?feat=directlink
This requires a more complex casting shape to get the belt into place,
and a separate end cover. It also puts the bearing a long way from the
belt tension load.

The third design uses the second bearing again, but in a better place.
https://picasaweb.google.com/lh/photo/X9ZXwL-oMXpF9cc6wAIbQNMTjNZETYmyPJy0liipFm0?feat=directlink
This design is growing on me, the only problem being that I can't
quite see how to retain the bearing outer race in the casting. It has
a nice direct drive from the belt to the ballnut.

I think the first option looks like the best, if it can fit. For
reference I have a 40mm OD on the ballnut and a 76mm diameter hole
90mm deep in the machine bed. This means the protrusion to the left of
the casting in the pictures has to be shorter than 90mm and less than
75mm dia.

-- 
atp
If you can't fix it, you don't own it.
http://www.ifixit.com/Manifesto

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