1 inch printed linear guide

Not just a theoretical design. printed and tested.

First print at 10% infill to check fit.

BOM

2040 Bosch aluminum extrusion
6 pieces M8 x 50mm bolt and lock nut
4 pieces M6 x 50mm bolt and lock nut
6 pieces 608zz bearing
2 pieces print part

Print 2 pieces
cut your extrusion to desired length between 50-100mm is fine. whatever works for you.
tap the end holes for m6 thread. Use lube when cutting the screws. This will serve to bolt the plastic on the aluminum as per the photo

bolt in bearings

Use as needed.

Included the DesignSpark Mechanical solid model CAD file so you can mod it or adjust as you like.

Inspired by Mark Reim design on Precious Plastic forum.