Many thanks for the reply Jazz. Will definitely save me a few quid using 5 series instead of ecocast where i can, and i will be ditching the big extrusion in favour of steel box.

I've hit a bit of a problem...I realised that I was massively optimistic when sizing my machine in relation to the actual space i've got. I could fit the machine but would have only a few millimetres clearance between the wall and access will be a nightmare. Therefore I have to reduce the width of the machine and position it elsewhere.

I can see 2 ways of doing this...

Type 1 : moving the x screws to above the x rails. This means the y rails will always now be that extra bit higher and the whole machine looks a bit less solid. I tried running the x screws threw the space between the y rails but then it becomes even more tall as i've obviously got to consider the y screw and motor positioning.

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Type 2: moving the x screws inside the x rails. i thought i could actually then use the machine in 2 configs. config 1 with a bed above the bearing plates when i need full width of machine.

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Then config 2 when i need strength and want to cut below the x rails instead of above. When using config 2 I would lower the piece of plate which the y rails are attached to (sorry..haven't done that in sketch).

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which do you think would be the best way to go?

if i went with type 2, when i lower the plate with y rails on them, would this be a major hassle each time for set-up? i thought i could use a few other pieces to hold the gantry sides relative to each other, unbolt the y plate and then bolt back in lower down.

p.s. these sketches are just to consider the 2 options and obviously there are loads of things missing.

as always, any replies much appreciated.