Aluminum router build - Could use some input

[routercnc]

To help you get more feedback I've dropped a screengrab from your site into this post - hope this is OK.

Here is your version 1:


Here is your version 2:


If you are keen to stay with supported rails and aluminium extrusion then this is a pretty good layout, and much better than the first one. My view is that you will be able to cut wood easily and accurately, and the occasional bit of aluminium.

But if you end up doing a lot of aluminium then you will find that this machine is not enough. An upgrade to profile linear rails on at least Y and Z is recommended, the gantry sections are too small and not joined to each other (e.g at least a plate over the back), and the X axis stepper motors are mounted off long brackets.

With the layout you have now I would look at moving the X ballscrews outwards and down, level with the supported rails. Then extend the small horizontal plate which the gantry sits outwards and screw the ballnut to the underside of it. There are other variations but you get the idea. This will enable you to mount the motors nearer to the frame, effectively stiffening the X direction when cutting. If this is too big a change then at least make the small plates on the outside much bigger and triangulate up to the motor position.