Jeff's 1000 x 800 Gantry Router Design & Build

[JeffZ]

I rendered a few more options. Maybe someone can share more insight.

215mm high gantry:
Option 1 (120x80 + 160x40)
This is the closest to what I currently have.
Not really much more expensive. Everything (motors, bearings) still fits neatly behind the gantry.


255mm high gantry:
Option 2 (160x80 + 160x40)
Fairly similar, but 40mm higher.


Option 3 (120x80 + 120x80)
Using identical extrusions.


Option 4 (120x80 + 160x80)
The expensive option.

[NB70]

If you use a certain size aluminium profile for the gantry (90 by 45 mm I think) you can mount the BK/BF ballscrew supports directly to it, which makes things easier.

[JeffZ]

If you use a certain size aluminium profile for the gantry (90 by 45 mm I think) you can mount the BK/BF ballscrew supports directly to it, which makes things easier.

My supplier does offer 45mm (B-Type) extrusions, but the choice is very limited.
Using my supplier, the only sensible option is the one you're showing, using 2 45x90 extrusions for a 90x135 gantry.

I prefer the 40mm (I-Type) extrusions. They're thicker, easier to tap, there's more compatible hardware, and I can get them in larger configurations, such as 160x80 and 120x80.
I don't mind using the FK/FF bearings, but you're definitely right that using BK/BF, bolted directly to an extrusion is both easier and more adjustable.