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[A_Camera]

All my extrusions are exactly 1000mm

All my linear rails are exactly 1000mm

All my ball screws are exactly 1000mm

You kind of see my problem - i can understand how the 'linear and ball screw kit worked - but it was never for my profile of extrusions!!

To be fair (as I like to say!) why would i not assume that the ball screws would be longer, they are when you buy them separately

Oh, just to make you smile, laugh or cry? Why did no one tell me that if you take the nut off the ball screw, that all the bearings fall out! What a crap design

WoodKnot

I actually don't see the problem with those lengths. With those lengths you can indeed get the full length movement, which is 1000 - 160 = 840mm. There is no such rule that screws must me longer than the rails. As I said before, it depends on the design, but you always lose at least as much as the carriages take (normally more) so why would there be a problem? The 1605 should be machined like this:

Attachment 30161

So from the full 1000mm you lose 11 + 39 + 15 = 65mm which means that you have 935mm movement and that is more than enough for your 1000mm rails. ...but you can't build that on a single 80mm wide extrusion, so you have to come up with a better solution. Anyway, we need more details, MUCH more details.

If you absolutely want longer screws, one solution is to cut off a bit of the rails. The length is easy to shorten, just use an angle grinder. But like I said, it isn't necessary to have longer screws at all.

I think by the way that I indeed mentioned NOT to remove the nut, and be careful when installing the carriages because the balls will fall out. But... if that happened, you could collect them all, clean everything and assemble all together again. It may take time, but no big deal. I think you can even buy balls only, in case you have lost some. Here is an example of a seller:

https://www.aliexpress.com/item/1005001533634944.html but DON´T buy any without you checked carefully the size and know if you really need some. Note that I have nothing to do with this seller and never had to buy any yet.