I finally had a chance to watch. Very cool project!
I like your machinist buddy's idea of green Loctite. I have used Loctite 680 to fit bushings into slip fit bores, and once it sets, they don't move. 680 is good for up to 0.015" clearance. Sounds like your application would be better with 641, which is for closer fits and recommended where disassembly might be required.
The only thing I wonder about with using a band saw frame for a louver press is the section of the backbone is kind of skinny. Granted, it worked against the blade tension when it was used as a saw, but I'm not sure how the loads compare. I think that's why the Mittler Bros. plans are for such a huge frame...they rate theirs for something like 16 gauge mild steel with a 5" louver, and it's a 48" throat. I have 2" louver dies for my lever press, and the tonnage is pretty low in 0.050" and 0.063" aluminum...but it's something to think about if you get to a situation where you're doing big/heavy stuff.
Last edited by Graham08; 05-25-2016 at 09:39 AM.