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The customer's thought was, that the ears holding the roller axle were possibly mushrooming or pounding out over time, but there was no real evidence. If any did occur, it was because the bore was slightly undersize, causing the lifter pieces to stick. So we had to adjust the machined tolerance...

It is completly machined from bar. It is a T6 temper.

The customer is really insisting on this and cost doesn't seem to be a deteriant. I just want to make sure we do not create a new problem.

We are currently manufacturing a part out of 6061. The part is very similar to a roller lifter for an automotive engine in shape, and how it must perform. The part is being stressed in compression and also slightly side loaded. There is also lash in the assembly to make up for heat. The part...