Thanks for the feedback. Hmm I might have posted before about the big 3D foam milling, probably not this particular project though, see pic.

I’ll start to look into the custom brake On/off coding and see if its something I can think incorporate without too much hair loss :). Yeah bigger motor could do, similarly the gearing as not concerned with speed just needs to work within the motors torque sweet spot.

I was actually thinking not for this machine but another about making a big manual 4th/5th axis trunnion for a post lockdown job coming in. Something in which I can manually orientate large foam blocks, to orientate the part to mill a 5 sided objects using indexing milling strategies. I can just program each face separately, orientate the block, lock it off and run the file. As these will be in foam a small amount of rotational deviation will be ok and saves me tonnes of work and money trying to make a electromechanical version at short notice. As long as the tool tip is set accurately to axis centre/s should be ok.
Click image for larger version. 

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