Jazz thank you for your post, this makes a lot of sense, you've reassured me re the servos. I've decided on using the analog interface with Linux CNC, mesa 7i92 and 7i77 with the controller closing the outer loop. I might need some help with the tuning. I've bought 600w for the X and Y, I have also committed to the BT30 spindle with a 1.8 kw servo.

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Waiting for the servo for the spindle, pneumatic cylinder and mesa cards.

Made a start on the pneumatics, I've gone with a "mist cooling" system using the water filter approach I found on the here, works well.

Got a lot of time consuming jobs done, filled the spindle head with epoxy granite, got the y-axis movement working. Made a few chips with jogging.

Next major problem is protecting the ways from chips, I've seen several designs. Would anyone be interested on collaborating on a way cover design?

I've seen a few designs:

Chris DePrisco made some with sheet metal: https://www.youtube.com/watch?v=3GSEayp8Ioo
This looks very labour intensive

This looks less labour intensive and less skilled, could potentially 3D print the sides: https://www.youtube.com/watch?v=G2DJ8RQy4D4

This project (which is a bigger, much more polished version of mine) uses way covers from aliexpress (I found a link and I think they cost about £400), this could be emulated by putting sheet metal on cheaper bellow way covers: https://www.youtube.com/watch?v=nTC5gWVmt0o

Then the simplest option is using rubber or a fixed cover with acrylic. Thoughts on this?