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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...

The epoxy goes on the rail mounting surface, the guy in the video is using the ally profile as a reference, dont like this unless it's been machined to be flat, you should be using a precision...

Most people just use the standard box section, if you are welding there will be distortion you can reduce this somewhat by just stitch welding it, doesn't have to be full weld. the distortion in the...

There's a really useful motor/ballscrew calculator spreadsheet somewhere on this forum which I found really useful, though I can't seem to find it at the mo. - worth digging out and putting in your...

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...

Ah, Tata Steel product! Can I ask where did you get it?
I would have chosen their Celsius 355 product instead, which is already stress relieved.

Also, you can't just bolt steel tubes and expect a...

Black Beard - take a look at my "Avor" build. I wouldn't necessarily recommend that you (or anyone else) tries to copy it, but you might get a feel for the kinds of things that go into a machine like...

Hi B3
Welcome to the forum
The first rule of any build is not to buy any of the electrics until you have everything designed in CAD/Sketchup. then offer it up for the guys to look over, they will...

Welcome BBB

First advice I would give is be realistic and honest with yourself about what you will use the machine for i.e. a router if designed carefully will be good for wood, plastics and...