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07-01-2014 #10
If the rails are on the bottom surface then the bearings, i.e. your supporting points, are closer to the tool/bed. The overhang is therefore reduced, so the stiffness is correspondingly higher. It does however make mounting them on epoxy more challenging - although you could conceivably mount the Y rails and X bearing blocks on the same epoxy leveled surface and get very good accuracy. I'd try drawing both orientations and see which looks the most promising.
I tend to agree - there becomes a point when an extra couple of mm of epoxy doesn't cost much compared to the added material/time required to get the frame more accurate. The epoxy is pretty strong/hard and the damping properties may be useful, so I wouldn't be too concerned about minimizing the thickness, within reason. If you look in my build log the epoxy is quite thick, but don't treat that build log as gospel - there's plenty of room for improvement.
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