I went through the exact same as you. I finally took that aluminum cover off and took it to a belt sander and really shaved a bunch off of it. I made sure the rod was adjusted up enough that I could still get good tension with the slide lever. After that, no more noise. As for your bearings, it might be a good idea to take your saw apart per the video and do a good clean and grease on them. It's not a tough job, just time consuming. A Saturday afternoon. I did it on mine using the Valvoline synthetic grease and a pipe cleaner. It made a lot of difference in vibration and noise. All scroll saws will vibrate at some speed or another. A lot of it can depend on how you have the saw mounted and positioned in your shop. If you don't move it much, as has been mentioned, a bag of sand on the lower rungs of the stand will take most of the vibration out of it. The DW is a very good saw so don't give up on it unless you just want a new saw. I started with one and then moved on up the quality ladder as good used ones came available. I now have what I feel to be the best their is.