There's not a lot of progress to report, but thank you kindly for your support.
It took only a few minutes to remove the meniscus using a course file, because there was 10mm each side of the rail it meant there was no need to get it perfectly flat across the whole width. I did run a bead of liquid nails down each side of the epoxy just to give a nice transition onto the metal.
Got the rails on, one support beam painted, 20mm aluminium gantry support bracket fitted and ballnut bracket attached.
Ball screw temporarily installed just to show actual position. Tried to keep rail and ballscrew in same horizontal plane as much as possible.
I had to regrind some drills to make counter boring tools for the cap head screws.
Attachment 11588Attachment 11589Attachment 11590Attachment 11591Attachment 11592
Showing end of beam with rail, epoxy, 6mm internal flat bar to give extra thickness for rail mounting screws, glued it in with Gorilla Glue and worked great.
Attachment 11593