Thanks Jazzcnc, Jonathan and routercnc for the comments on the Y and Z axis. Re-design in process to include using smaller seperate extrusions to reduce
alignment issues and enable the Y axis ballscrew and nut to be located under the Y axis rails and reduce the distance to the Z axis assembly.

Talking about the alignment of the axes for a CNC, I had the idea to buy a large thick piece of float glass (10mm x 1500 x 1000) to provide my "flat" surface from
which I could then make accurate measurements using a dial micrometer. By measuring the surface first, one could reasonably then account for the variations in the surface when measuring...

Regards
Mike