New and in need of wisdom

[Jonathan]

Steel frame is almost certainly the way to go mainly because it's cheaper if you buy it in the standard 7.5m length. Don't be afraid of welding!

Software - CAD isn't a problem, so no worries there. CAM/toolpath software I have seen is the Vetric stuff and VCarve Pro appears to be what I need (I've also been playing with Cut3D already just to try stuff out) the and Mach 3 for the machine control? Any others out there?

Since you've already used 3DSmax, you shouldn't find it too difficult to use CNCToolkit which is a free script for 3DS that creates toolpaths up to 6-axis. It's not the easiest CAM program (if you can call it a program) to use, but I think that's mainly due to how different 3DS is to most CAD programs. Having said that if you only need to to 2.5D milling, then there's no point overcomplicating the process - just use CamBam, one of Vectric's programs or similar.

Oh and cutting carbon/glass re-inforced resins and plastics - can this be done, as I also do some composite work?

No problem, with the right tool:

http://www.mycncuk.com/forums/showth...ll=1#post29541