Ralph, I think your fear of prox switches is not justified. I have measured every shopbot I have visited for the past several years, employing several kinds of prox switches.
The zero certainty of a prox switch that is set correctly is about 0.002" which is approximately 0.05mm. That is double the accuracy you are getting.
I have not yet found a properly setup PRS Alpha ShopBot that did not get 0.002" (0.05mm) repeatability in home finding when I measured it.
With the copper sweat fitting zero method (or a super zero) the repeatability is 0.001" (0.025mm), which is four times what you are getting. Quite often it comes back as 0.000".
Mark- There are several threads on the forum about super-zeros. Those "should" get the 0.001" (0.025) accuracy on the corner of the stock. I am having a machine shop build me one to try (its nice to have a shopbot to trade favors eh?) but I have not gotten it yet. You can trust I will be testing it the same as the other techniques.
Hope that helps-
D
"The best thing about building something new is either you succeed or learn something. Its a win-win situation."
--Greg Westbrook