Brief update.

I've been working on the bed making up brackets and crossmembers. The previous bed was a piece of 18mm ply with very little support. I intend to make this one much better and with the move from single central ballscrew to twin X drive I can now use all the space in the middle.

My chopsaw (with TCT blade) made short work of the aluminium angle brackets (1.25"x1.25"x1/4"), and then on to using the machine for the first time to cut all the holes out.
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I had to rig up a quick bed support for the vice to machine the holes.
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Putting it together.
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The bed assembled . . .
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This is a multi-function bed with vice work at one end, flat work in the middle, and limited 'end-on' work at the far end. Or everything can be stripped and a wooden sacrifical bed added.

Running a DTI over the bed (in spindle) shows there is some uneven-ness which was confirmed with a flat edge so I plan to lightly skim it. This will only be as level as the rails allow but will be better than the current condition.

I've taken some machine stiffness measurements but I'll put those in another post later to keep this one for the build.

Thanks for the all positive comments - keeps me going !