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The Hiwin bearings I used needed the plastic keeper in place otherwise the balls fell out, I found out the hard way. I found that by being careful the bearings would slide onto the rail if it was...

Nah at this size don't bother using differant size screws just go with 16mm all round and use 10mm pitch for X & Y 5mm on Z axis.
Critical speed isn't an issue if using steppers as you'll never get...

If you order ball screws then refer to the 'standard machining' diagram and request dimension F = 30 mm, this will give you enough length to fit a pulley otherwise it's a bit short.

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It's one or both of these

Don't stress over the gantry weight you'll be ok upto 80Kg with 2 motors using the correct pitch, motors,drives,voltage etc.

Regards the gantry then again don't stress. Any of the designs you...

Yes you can use Hiwin rails vertical or horizontal, just make sure you can get them lined up exactly in both planes.

I assumed same might apply to diagonals in the corners, also it was suggested by silyavski to put the diagonals so they were about 1/3 way up the legs and also supported the upper rail at more places...

Sounds like you will have no trouble with the build. As usual, get some CAD drawings uploaded for comment.

Vagelis,

The ground side of the rail is designed to butt up to a machined vertical face so that if the machined face is straight then the rail will also be straight. The carriages have a ground...