King Midas mill conversion

[diy-john]

Yes, learning by doing. One year from start of thread now, and we are here.

Please how would you see a 'final X-axis build' like this?

1) Make sort of table-top, out of 15mm aluminium (or possibly 2 x 15mm = 30mm, even 3x15mm=45 mm possible?)
1.1) The top is level with current table top
1.2) Size of original table is 500mm x 130 mm
1.3) Size of new table top is extends current table top quite substantially (60mm at the mill-side of table, more at front)
- will not reduce travel, though.



Reasons why I would want a larger table top:
- keep chips away from ball screw
- perhaps aid attaching a larger item on table (would drill + tap holes. Threaded holes covered with plastic plugs, except when in use)
- add rigidity to X-axis
- add rigidity to motor mount

2) On either side of table, would have 15mm thick aluminium plates, like in photo (except photo has 5mm thick aluminium)
3) The "boxed sections" at either end of table, would add 15mm thick aluminium blocks between original table end, and bearing mounts.
- purpose: add rigidity both longitudal and horizontal


3.1) Motor mount: 2x15mm thick aluminium
- secure motor to larger 15mm thick table top (from above)

4) Bearing mounts on either end of table: 2 x 15mm thick aluminium

I see difficulties with the build in many ways. I am sure one would have been happier with a little bigger machine to start with. But this is what I have, and it will be a nice machine.

But do you see issues with this structure? Would one regret the larger table top?

Would appreciate comments :D

Thanks!