1220 × 2440 build

[JAZZCNC]

What would you recommend instead Dean? I keep thinking about the logistics of it, I don't have a forklift at home haha

Well all can say is build it stronger or should say Stiffer. If your limited with logistics then build it sections so can be easily moved. It will add another level of complexity because still need to maintain accuracy which is harder to do with more pieces.
Going to say this again because cannot stress enough. Your Gantry design is WEAK and if you build this it will show in the quality of finish.

The Gantry and Z axis are key areas. Malcolm as already mentioned to his pain that Z axis is key area and soon shows any weakness in the cut.
I don't agree that is Gantry is over built and changing to lighter Section profile wouldn't give any better performance really and could potentially cause other issues with resonance when cutting deep or hard materials.
Better having strong gantry that is little heavier than light gantry that will flex when cutting hard. If higher feeds are required then better to size the screws or motors to suit rather than under build.

Under building because of Logistics or weight is just going to compromise the machine performance. Better to think smarter and design around any restrictions.

[malcolm01]

I recon my gantry weighs at least 100kg, surely reducing that alittle with a lighter profile aluminium wouldn't hurt??

[JAZZCNC]

I recon my gantry weighs at least 100kg, surely reducing that alittle with a lighter profile aluminium wouldn't hurt??

Ok I guess your main profile is 160x40 and top/bottom profile 80x40.? The weight difference between HD and light for 160x40 is 3Kg per meter and 2.5kg perM on 80x40.
So lets say gantry is 1500mm wide so in total your only saving approx 12kg and this won't make a huge difference in performance. The extra strength it provides will be more beneficial when cuttng hard than the any slight speed it may gain.