Ok, Seeing as how my hex rail and skate board bearings idea is going to take me too much time, I've had to rethink how I want to build my machine. I've spent most of the night looking through the Igus website debating which direction I would like to jump. Binding won't be an issue in my design. I have three options that I see I could use on a gantry router.
http://www.igus.com/show_dw.asp
#1 Use the Drylin W 10mm 40mm wide double rail on both the X and Y axis so that there would be 2 double rails per axis. I think I would be fighting alignment problems after reading some of the other posts. Total cost on rails and shuttles about 450 bucks. Static load rating 1079 lbs which is with a complete carrage assembly.
#2 Use the Drylin W Square 20mm single rails for the X and Y axis 2 rails per axis. They claim that the square is better than the round rails for friction and load capacity. This setup would run me about 500 bucks. Static load rating is 719 lbs per shuttle. Looking like this would be my best bet.
http://www.igus.com/show_dt.asp
#3 Use the Drylin T 15mm rail with 2 rails per axis like #2 option. They look like they would be a good route to take other than the price. This option would set me back about 750 bucks but the adjustability would be nice. The static load rating is 900 lbs top and bottom and 450 for the side which is going to be the highest load rating out of any of the options and probably the most adjustable.
So is 250 bucks worth the extra adjustability and load capacity for a machine that might see a little bit of aluminum and steel milling.