So off comes the Z axis and I have a new front plate made to try solve the problem of not being able to tighten the supported rail. This works fine but then I realise despite ordering a machine with 200mm of Z travel I only really have about 175mm. Making it very tight for some of the jobs I have in mind. Thanks for that Strike. So I think sod it, I'll design my own. Can't be that hard can it.

Here's the result...

Click image for larger version.  Name: New Z Axis (1).jpg  Views: 1128  Size: 129.4 KB  ID: 7696 Click image for larger version.  Name: New Z Axis (2).jpg  Views: 944  Size: 132.2 KB  ID: 7697 Click image for larger version.  Name: New Z Axis (3).jpg  Views: 1234  Size: 109.9 KB  ID: 7698

Bit over engineered for the machine with 25mm linear rails and a 25mm thick ecocast front plate but overkill never hurts. It does slow you down though so will no doubt have to dial the speeds/acceleration back a tad after this but I'd rather do that and have accuracy with a good finish.

And on the machine:

Click image for larger version.  Name: New Z Axis (4).jpg  Views: 1192  Size: 116.8 KB  ID: 7699 Click image for larger version.  Name: New Z Axis (5).jpg  Views: 958  Size: 101.9 KB  ID: 7700 Click image for larger version.  Name: New Z Axis (6).jpg  Views: 933  Size: 114.5 KB  ID: 7701

Looks good so far, happy with that. You can also spot the X and Y ballscrews in those shots. These now have the correct ballscrews mounts with angular contact bearings instead of the Strike's cheap substitute - round rail supports with captured regular chinese ballrace bearings. Those will slop about like crazy with a bit of wear on them. Strike may now be out of business but Merchant Dice use the same method in some of their machines so watch out for that.