Man - I cannot believe how long it has taken for me to find the time to upload some more to this thread.

I have reworked the Z axis a little to take on some of the comments - images attached bellow and as usual comments more than welcome.

The main changes are double plates to attach the y axis uprights to the bearing blocks to allow for adjustment and an increase from 100mm from the bottom of the z axis mount to the top of the bed to 150, giving 132mm clear if an 18mm sacrificial board is used on top of the bed.

I am now quite close to saving up enough to buy the first batch of parts and could do with some guidance on ordering bespoke end machine for the ball screws to allow for the pulleys to be mounted. Jazz had mentioned having them machined longer than usual - would about 100mm extra suffice?? Also did you have the diameter machined down too to receive the pullies?? many thanks in advanceClick image for larger version. 

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