A sufficiently strong machine

[Jonathan]

1. To stiffen up Z and Y ( when in action together ), i was thinking off adding rails to the inside edge of the X top support. ( i may want to add an impact head to it in the future ). Any opinions ?

It's hard enough to align 2 rails let alone four. If you really need the higher load ratings, it's easier to just use bigger rails.

2. any idea when the files will be available, am eager to have a crack at this.

Soon. Sasha's still sorting them out but he's more interested in making the enclosure for the machine at the moment!

- 2 x 100x100 steel box for the gantry

Could do, but clearly that makes getting an accurate surface to mount the rails on more difficult. An early design for this machine did use 60*60 box section, but we decided not to use it as aluminium is much easier to machine.

-The bearing blocks and rails on the gantry to be at the upper side/or at the lower side/ so i can use epoxy and level them easy

Definately lower side as you want to keep them as close to the bed as you can to minimize the overhang.

-2x ballscrews at the gantry near the rails

I presume you're referring to the Y-axis? If so then yes it will make a noticeable difference to the stiffness of the Y-axis, but bear in mind it's already exceptionally strong so it's by no means mandatory. You could achieve the same by increasing the spacing of the Y-axis bearing blocks quite significantly.

What worries me most is the Z, making the z box and adjusting rails and fitting everything in place there. maybe using some ready box section and fit the spindle inside and fix the bearing blocks to the sides of it.

We used separate plates as they can be adjusted to get the rails parallel. Also it means you can machine features inside the Z-axis and you're not restricted to limited standard sizes.