I'm OK with blunt so don't worry.

Individual PSUs running @60V @6A to the motors so I think they'll be OK.

Not sure about the high feed rates in softer material statement though - I haven't worked with wood previously but have cut plastics before and feeds / speeds can be adjusted accordingly.

40mm box was for the frame only - was going to use 125 x 20mm BMS for the gantry sides, with 50 x 20mm flat bar as anchor points and mounting. Can beef up the frame to 60 box no probs, but was going to anchor to the floor after leveling so thought it didn't matter about 40 box.

Chose 1605 deliberately as I though accuracy was was a better trade off. In no rush to make things as this is going to be a hobby not a career.

Will re-start the design on the weekend and will post it bit by bit. Use Inventor to draw 3D so will have to draw all up from fresh - so won't be quick