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I'm hunting for appropriate material to make a set of new worm bearing shims. Need a variety of really thin stuff (.003, .005, .010) that is relatively tough and will seal the worm cover and allow for future adjustment by removing shims.
Garden variety gasket material is way too thick.
McMaster has plastic shim in sheets made of polyester. Would this be a good choice?

http://www.mcmaster.com/#standard-shims/=qkhcwj

Thanks.

how about aluminium flashing material?

I'd go with steel or brass shim stock. McMaster has some sets and Amazon also has a variety of thicknesses and materials in sets. Here is an Amazon brass assortment and if you search for "shim stock assortment", various other materials will also come up.

I'd strongly recommend going with HH56's suggestion; buy an assortment of steel or brass shim stock. The thinner materials can be relatively easily cut to shape with good scissors and the holes punched.

Interesting. Because the cover has been the source of past leaks, I dismissed brass/steel wondering whether they would have the slight "give" necessary to form a seal and whether those materials would be easily fabricated into a gasket and whether they could easily be torn out for future adjustment. That said, coming from two masters, brass is it.
Thanks gents.

Perhaps the cover plate has been warped or something nicked. Maybe your machinist could check the cover on a surface plate or possibly a piece of glass is flat enough to see if it is straight.

Mark, If you have a Grainger store nearby, they might be a good source for sheet brass in varying thickness.

(o{}o)

Also, hobby shops may be a good place to look, locally.

You should put in some sealer on the metal. We used a product call Hylomar to seal racing transmissions metal to metal on the case. It is similar to rubber cement. It is available from a hard core racing shop like Pegasus.