Well here goes... Aluminium frame router design

[CharlieRam]

Well that's been a few days of discovery I won't forget in a hurry!

I stripped the carriage again, gave it a good clean and scotchbrite on all ports and ball ways, reassembled the carriage temporarily, put it back on the rail and started to slide it up and down to check the tightness and then....the end came off and 120 balls all over the floor! F$%k, I found 118 of them and still had 2 spare from Lee luckily.

Oh yeah, I also decided to check the other carriages now I'm confident the balls wont go flying if I remove them a couple of the others seem to have one ball missing too!

Cleaned it all again and secured it properly this time but it still felt tight, that is when I noticed the carriages looked slightly different on the exterior, so I checked the serial numbers again, both are DFH20A but the nice fitting ones have S01411040 and the tight one has S01207841. Does anyone know if any of these numbers signify the preload, I'm thinking I may have a higher preload carriage or is it just a batch number and one was made at a different time with not such a good QC?

More Importantly, will it affect the build having a mis matched carriage?

Cheers, Charlie