3 Axis CNC router

[Jonathan]

I am now quite close to saving up enough to buy the first batch of parts and could do with some guidance on ordering bespoke end machine for the ball screws to allow for the pulleys to be mounted. Jazz had mentioned having them machined longer than usual - would about 100mm extra suffice?? Also did you have the diameter machined down too to receive the pullies?? many thanks in advance

To add pulleys you want to increase the length of the bit the pulley mounts on as on the standard drawings it's 15mm, so I always ask Ghai to 'increase dimension F on end machining to 25mm for pulley'. That makes it much easier to align the motor and screw pulley, but clearly you'll need to add 10mm to the length of screw to compensate...The standard diameter for that bit is 10mm, but you may want to consider having that 8mm (same as motors) you can easily swap the pulleys round if required.
This is the end-machining drawing Chai (linearmotionbearings2008) sent me:

Has anyone done this in the past or did you all have metal working mills and lathes in your garages and sheds?!

Yep, I got the mill first and used that to make the router. My milling machine was £320 on eBay from someone local, so if you can find a good deal I strongly advise getting one as they're so useful just in general. You might even be able to get one second hand, make the router, flog it and be in profit.