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A1:

• Look at Lily bearings (https://www.lily-bearing.com/)
• Look at silverthin or cadon bearings
• Thin Section bearings
• X contact bearings
• Either use 2 angular contact bearings
• Switch standoffs for OTS

A2:

• Add more meat to the connection between the pulley and the joint (bolts in new holes in the poulley)
• Look at the joint again
• Reduce the length of the shaft, reposition the bearings

A3 and A4:

A5 and A6:

•  Overall review design of joints
• Tap into plate for encoder
• Build the gearbox without the inner ridge first, then see if you need the ridge