Thanks for the input guys.

Time for an update,

I have decided to stick with the single screw on the x for now, this is mainly due to the additional cost. Also it will be easy to add an additional screw at a later date if I'm not happy with the results.

All screws will be direct drive to the steppers.

I will be using 16mm screws all round, 10mm pitch on the X and Y and 5mm on the Z.

I will use my existing drivers and power supply @ 40V.

Z Assembly is going to be changed a bit to reduce flex, I will be increasing the distance between the bearings and extending the front plate holding the router. The stepper and ball screw will also be mounted there (I will post up a new drawing soon).

I know that alot of these things go against what has already been discussed but at the moment funds wont stretch far enough to make all the changes now. Besides most if not all the fun for me in building these things is working on upgrades and improvements.

Upgrades as funds are available will include (probably in the following order);

Drivers and Power Supply @ 75V.

Additional screw on the X axis if required.

Spinning Ballnuts on X axis.

Timing belt and pully to drive X and Y possibly Z.

Water cooled spindle.

4th Axis.

This is going to be an ongoing project, at 1st I will have to run lower feed rates and smaller pass depths untill upgrades get made.

I should be able to order all the steel in a few weeks, then hopefully the following month will be the linears and ballscrews.

The best I can find the cut Alli plate (without going to a machine shop) for is +-2mm. The size doesnt worry as much as if the things are going to be square/parallel. Johnathan how do you feel about making the Z Assembly, Router mount and 2 ballnut holders for me .

After that is all together I should be able to machine some ali myself if I stick to the center of the bed.

Again thanks all for the help guys