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Actually, taking each home switch into separate inputs on the CSMIO isn't a big issue as it has plenty of inputs available. It also means that you can set Mach3 to home more than one axis at a time,...

I call my long axis X, and gantry is Y axis. Need to be clear about that to avoid confusion! X tubes are 100x50, supported at a number of points along their length to the main machine frame. No...

Seeing that you've quoted my design, I might as well jump in here! I am extremely pleased with the way my AVOR machine has worked out - much better than planned. As a model engineer rather than a...

Very convenient that the CSMIO is 5V output! Have you also used differential wiring to the 752s? It's not shown in the 752 manual, but it just means taking the two CSMIO * and - terminals to the two...

No problem - that's what I use. Haven't had a shock off it yet! I use a movable touchplate in conjunction with a fixed plate set into the bed which makes tool-changing in the middle of a job much...

Simple answer is that the CSMIO is designed for more sophisticated machines than a typical home-built router. Doing it this way means that you could use entirely separate power supplies for the CSMIO...

I know that you've had a look at my write-up already. I used 3mm wall thickness. If I were doing it again, I might have used 4mm for some of the parts (like anything that has a rail bolted you it)...

Couple of odd comments:

IP/M is very happy with direct connection of prox switches running on 24V. Works well.

IP/M drives the usual stepper drivers directly without needing any resistors. Use...

You can use one sensor on the moving part and two targets, one at each end. In normal operation, this acts as the limit switch but during homing, Mach3 and the IP-M know that it is being used for...

I realise that I have to trust some amount of hardware and software. However, I am more concerned about triggering the "start" function by accident, which would move the spindle to the next position...

No, I never turn off the VFD during tool change. Would probably double tool-change time, waiting for VFD to power down/run up. I'm with Doddy - life's too short...

One possible reason for different temperatures for the two motors on your Y axis is whether or not you have "half current when stationary" selected on both. A lot of stepper drivers have this option...

Looks about right to me.

Microstepping - yes, half-stepping probably gives you as good a resolution as you need for a router, but the thing will run like marbles in a cement mixer! Go to x8 microstepping and it runs much...

Bert - I don't think that the sensor needs to be on the moving part - I can imagine a rotating blade on the end of the ballscrew with a fixed sensor next to it.

Andrew - the term probably comes...

Are the "units per" settings in the Mach3 config correct, or did someone use cm instead of mm there?

Looks like an old lathe headstock and tailstock. Headstock spindle would have been driven by a stepped pulley between the bearings. Don't know about that thrust bearing arrangement at the back end!

Be aware that using an EMI filter can cause problems if your supply comes via a RCD, as it can cause unbalanced live/neutral currents. I have an inverter with built-in EMI filter and there is a...

If you are using the common switch-mode power supplies (these are generally contained in a single box, lighter weight, and cheaper) then it is very important not to exceed the rated current. If you...

A good way to seal the leaks around a dam before you pour your epoxy is to make up a very small amount of the epoxy and using a small brush or similar just go round the inside of the dam brushing the...

Yes, 5 thou is definitely too much. Half-thou is not quite as much as the usual "thou per inch" rule of thumb, but then you are heating the bearing and I'm not quite sure how hot you can reasonably...

Just done some quick sums based on rough coefficient of expansion of steel. If your diameter difference is correct, then you will need a temperature difference of around 55C to get enough...

Are you using an external motion controller? Mach3? Which version? I ask because there are some known problems with at least the CSMIO controllers and certain versions of Mach3 that can give some...

Unless you are using very fancy pulleys with D-shaped holes, then the flat is only for a grub screw to bear against. It's not critical and you could always put a flat on with file (if soft enough) or...

Don't worry about the steel quality - I didn't! I just bought something from my local steel supplier, probably generic "construction" steel. Doubt if it's stress-relieved or anything else. It is...