Been doing some serious thinking over the past week or so and have decided to scale back my ambitions considerably. Was stuck between going for a 8060 or a 6040, then thought a 7050 might be the ideal compromise.

With that in mind, if I wanted to use profiles for the frame of the machine, what would people consider the minimum size of profile to use? I'm assuming that 4590 in an L configuration is fine for the gantry, but just wondered what I'd need for the long sides... I'd originally thought I'd use 80160s with the rails running along the top and the screws on the sides, now I wondering if that's a bit overkill and if I could get away with something smaller and obviously cheaper.
As stated ages ago, the design would be based off of AndyUKs but obviously using profile instead of the steel Andy used.

Cheers